Effects of powder reuse on the microstructure and mechanical behaviour of Al–Mg–Sc–Zr alloy processed by laser powder bed fusion (LPBF)

Cordova, Laura; Bor, Teunis Cornelis; Smit, Marc de; Carmignato, Simone; Campos, Mónica; Tinga, Tiedo

doi:10.1016/j.addma.2020.101625

Cited by 37 publications

(41 citation statements)

References 32 publications

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“…Analyses of cost per part as a function of number of parts are widespread in the AM community and show how reducing the overall cost of AM increases the size of production runs for which AM is economically feasible [52,336,337]. Such analyses have sparked numerous studies aimed at decreasing recurring AM costs, such as the reuse of feedstock powders [338].…”

Section: Economic Considerationsmentioning

confidence: 99%

Towards high-temperature applications of aluminium alloys enabled by additive manufacturing

Michi

Plotkowski

Shyam

et al. 2021

International Materials Reviews

131

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Research on powder-based additive manufacturing of aluminium alloys is rapidly increasing, and recent breakthroughs in printing of defect-free parts promise substantial movement beyond traditional Al-Si-Mg) systems. One potential technological advantage of aluminium additive manufacturing, however, has received little attention: the design of alloys for use at T >~200°C, or~1/2 of the absolute melting temperature of aluminium. Besides offering lightweighting and improved energy efficiency through replacement of ferrous, titanium, and nickel-based alloys at 200-450°C, development of such alloys will reduce economic roadblocks for widespread implementation of aluminium additive manufacturing. We herein review the existing additive manufacturing literature for three categories of potential hightemperature alloys, discuss strategies for optimizing microstructures for elevatedtemperature performance, and highlight gaps in current research. Although extensive microstructural characterisation has been performed on these alloys, we conclude that evaluations of their high-temperature mechanical properties and corrosion responses are severely deficient.

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Section: Economic Considerationsmentioning

confidence: 99%

Towards high-temperature applications of aluminium alloys enabled by additive manufacturing

Michi

Plotkowski

Shyam

et al. 2021

International Materials Reviews

131

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“…Two distinctive features of the powder set it apart from the virgin powders reported in the powder reuse literature. Therefore, it should be considered: Small powder particles (in the form of satellites and loose particles) are usually found in virgin powders [ 10 , 15 ]. Such powders during reuse are losing small particles.…”

Section: Discussionmentioning

confidence: 99%

“…Small powder particles (in the form of satellites and loose particles) are usually found in virgin powders [ 10 , 15 ]. Such powders during reuse are losing small particles.…”

Section: Discussionmentioning

confidence: 99%

“…There are many studies on powder reuse in LPBF, including nickel-based alloys [ 10 ], iron-based alloys [ 12 ], titanium-based alloys [ 13 ], and aluminium-based alloys. Recently, published works on aluminium-based alloys focus on the AlSi10Mg [ 14 ] and Al-Si-Sc-Zr [ 15 ]. The main findings of [ 15 ] have pertained to the mechanical properties (ultimate tensile strength (UTS) and elongation at the break of specimens, respectively, built with virgin and reused powder are 565 MPa, 13% and 537 MPa, 11%) and porosity (0.06% for samples made from virgin powder compared to 0.15% for samples made for the reused powder).…”

Section: Introductionmentioning

confidence: 99%

“…Recently, published works on aluminium-based alloys focus on the AlSi10Mg [ 14 ] and Al-Si-Sc-Zr [ 15 ]. The main findings of [ 15 ] have pertained to the mechanical properties (ultimate tensile strength (UTS) and elongation at the break of specimens, respectively, built with virgin and reused powder are 565 MPa, 13% and 537 MPa, 11%) and porosity (0.06% for samples made from virgin powder compared to 0.15% for samples made for the reused powder). In addition, the authors of [ 16 ] analysed properties of AlSi10Mg alloy aged in air and used for direct-energy deposition (DED); they found out that the increase in oxygen content influences the processability of the powder and the properties of the final specimens.…”

Section: Introductionmentioning

confidence: 99%

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Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

et al. 2022

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Additive manufacturing (AM) is dynamically developing and finding applications in different industries. The quality of input material is a part of the process and of the final product quality. That is why understanding the influence of powder reuse on the properties of bulk specimens is crucial for ensuring the repeatable AM process chain. The presented study investigated the possibility of continuous reuse of AlSi7Mg0.6 powder in the laser powder bed fusion process (LPBF). To date, there is no study of AlSi7Mg0.6 powder reuse in the LPBF process to be found in the literature. This study aims to respond to this gap. The five batches of AlSi7Mg0.6 powder and five bulk LPBF samples series were characterised using different techniques. The following characteristics of powders were analysed: the powder size distribution (PSD), the morphology (scanning electron microscopy—SEM), the flowability (rotating drum analysis), and laser light absorption (spectrophotometry). Bulk samples were characterised for microstructure (SEM), chemical composition (X-ray fluorescence spectrometry—XRF), porosity (computed tomography—CT) and mechanical properties (tensile, hardness). The powder was reused in subsequent processes without adding (recycling/rejuvenation) virgin powder (collective ageing powder reuse strategy). All tested powders (powders P0–P4) and bulk samples (series S0–S3) show repeatable properties, with changes observed within error limits. Samples manufactured within the fifth reuse cycle (series S4) showed some mean value changes of measured characteristics indicating initial degradation. However, these changes also mostly fit within error limits. Therefore, the collective ageing powder reuse strategy is considered to give repeatable LPBF process results and is recommended for the AlSi7Mg0.6 alloy within at least five consecutive LPBF processes.

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Alloy Design for Metal Additive Manufacturing

Dovgyy

Pham

2023

Additive Manufacturing Technology

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Effects of powder reuse on the microstructure and mechanical behaviour of Al–Mg–Sc–Zr alloy processed by laser powder bed fusion (LPBF)

Cited by 37 publications

References 32 publications

Towards high-temperature applications of aluminium alloys enabled by additive manufacturing

Towards high-temperature applications of aluminium alloys enabled by additive manufacturing

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

Alloy Design for Metal Additive Manufacturing

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