The Influence of Powder Reuse on the Properties of Laser Powder Bed‐Fused Stainless Steel 316L: A Review

Douglas, Rory; Lancaster, Robert; Jones, Thomas A.; Barnard, Nicholas; Adams, Jack

doi:10.1002/adem.202200596

Cited by 6 publications

(5 citation statements)

References 42 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Process-related physical metallurgical phenomena are highly sensitive to both process parameters and powders [150]. Thus, the LPBF technique needs meticulous machine calibration and quality control by regulating the situational variables associated with process inputs and powder conditions [54,[151][152][153].…”

Section: Lpbf Processing 221 Powder Preparationmentioning

confidence: 99%

Strategies and Outlook on Metal Matrix Composites Produced Using Laser Powder Bed Fusion: A Review

Kim,

Fang,

Kim

et al. 2023

Metals

View full text Add to dashboard Cite

Particle-reinforced metal matrix composites (MMCs) produced using the laser powder bed fusion (LPBF) technique have gained considerable attention because of their distinct attributes and properties in comparison with conventional manufacturing methods. Nevertheless, significant challenges persist with LPBF-fabricated MMCs: more design parameters over commercially available alloys and several defects resulting from inappropriate process conditions. These challenges arise from the intricate interaction of material- and process-related phenomena, requiring a fundamental understanding of the LPBF process to elucidate the microstructural evolution and underlying mechanisms of strengthening. This paper provides a comprehensive overview of these intricate phenomena and mechanisms, aiming to mitigate the process-related defects and facilitate the design of MMCs with enhanced mechanical properties. The material processing approach was suggested, covering from material design and LPBF to postprocessing. Furthermore, the role of in situ heat treatment on the microstructure evolution of MMCs was clarified, and several novel, potential strengthening theories were discussed for the LPBF-fabricated MMCs. The suggested strategies to address the challenges and design high-performance MMCs will offer an opportunity to develop promising LPBF-fabricated MMCs, while overcoming the material limitations of LPBF.

show abstract

Section: Lpbf Processing 221 Powder Preparationmentioning

confidence: 99%

Strategies and Outlook on Metal Matrix Composites Produced Using Laser Powder Bed Fusion: A Review

Kim,

Fang,

Kim

et al. 2023

Metals

View full text Add to dashboard Cite

show abstract

“…As for the total cost of L-PBF, it is dependent on the specific materials, building plate, inert gas, and other factors [21]. Generally, the powder cost takes up to 18% while the costs of machine and post-processing are 63% and 8%, respectively [19].…”

Section: Introductionmentioning

confidence: 99%

“…As above-mentioned, powder characterization, preparation, and reuse are vital for reducing manufacturing costs and ensuring printing quality and consistency. Given their importance, there are already several papers reviewing the recent progress [21,32]. Sun et al [32] have systematically reviewed the powder fabrication methods of Ti alloys, mainly focusing on the gas atomization (GA) process.…”

Section: Introductionmentioning

confidence: 99%

“…Yet the evolution beyond these properties is seldom discussed. Douglas et al [21] have reviewed the effect of powder reuse on the powder characteristics and part properties, however, the dynamical mechanical properties were not investigated in that work. To fill the gap, the present review mainly dedicates to investigating the three aspects of powders, including characterization, preparation, and powder reuse.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Sun,

Chen,

Liu

et al. 2023

Int. J. Extrem. Manuf.

View full text Add to dashboard Cite

Laser powder bed fusion (L-PBF) has attracted significant attention since its inception, providing unprecedented advantages to fabricate metallic components with complex geometry. The quality and performance of as-printed alloys is an intricate function consisting of numerous factors linking the feedstock powders, manufacturing, and post-treatment. As the starting materials, powders play a critical role in influencing the printing consistency, total fabrication cost, and mechanical properties. In consideration of its importance for L-PBF, the present review aims to review the recent progress on metallic powders for L-PBF focusing on powder characterization, powder fabrication, and powder reuse. The methods of powder characterization and fabrication were presented in the beginning by analyzing the principles and corresponding advantages and limitations. Subsequently, the effect of powder reuse on the powder characteristics and mechanical performance of L-PBF parts is analyzed focusing on steels, nickel-based superalloys, Ti and Ti alloys, and Al alloys. The evolution trend of powders and as-printed parts varies for different alloy systems based on the existing studies, which makes the proposal of a unified reuse protocol infeasible. Finally, perspectives are presented to cater to the increasing applications of AM technologies for future investigations. The present state-of-the-art work can pave the way for the broad industrial applications of L-PBF by enhancing printing consistency and reducing the total cost from the perspective of powders.

show abstract

“…However, most of the studies were conducted using alloy powders that are not used for building dental restorations. [11][12][13][14][15][16][17] There are limited studies in the literature about the effect of reused cobaltchromium (Co-Cr) alloy powders on sintered structures. Leban et al 2 reported that reusing Co-Cr alloy powder increased the hardness and porosity of the manufactured objects.…”

mentioning

confidence: 99%

The Effects of Reusing Cobalt-Chromium Alloy Powder on Its Mechanical Properties and Grain Size: An In Vitro Study

Ekren,

Ucar

2024

Int J Prosthodontics

View full text Add to dashboard Cite

To characterize material changes that may occur in virgin cobalt-chromium (Co-Cr) alloy powder when it is blended with alloy powders that have been reused multiple times. Materials and Methods: Initially, 20 kg of virgin Co-Cr powder was loaded into a laser-sintering device. The tensile test specimens were fabricated in the first (Group 1), fourth (Group 2), seventh (Group 3), tenth (Group 4), and thirteenth (Group 5) production cycles (N = 15). Prior to fabricating the specimens, powder alloy samples were collected from the powder bed for analysis. The tensile strength, elastic modulus, and percent elongation were calculated with tensile testing. Scanning electron microscopy and energy dispersive x-ray spectroscopy (SEM/EDS) and laser particle size distribution (LPSD) were used to analyze the alloy powder samples. The fracture surface of one tensile test specimen from each group was examined via SEM/EDS. One-way ANOVA followed by Dunnett T3 test was used for statistical analysis (α = .05). Results: No difference was observed between groups in terms of tensile strength. A statistically significant difference was observed between Groups 1 and 2 in terms of percent elongation. Groups 2 and 4 were statistically significantly different in terms of both elastic modulus and percent elongation (P ≤ .05). SEM images of the powder alloy showed noticeable differences with increasing numbers of cycles. SEM images and the EDS analysis of the fractured specimens were in accordance with the strength data. Conclusions: Reusing Co-Cr alloy powder increased the particle size distribution. However, there was no correlation between increased cycle number and the mechanical properties of the powder.

show abstract

The Influence of Powder Reuse on the Properties of Laser Powder Bed‐Fused Stainless Steel 316L: A Review

Cited by 6 publications

References 42 publications

Strategies and Outlook on Metal Matrix Composites Produced Using Laser Powder Bed Fusion: A Review

Strategies and Outlook on Metal Matrix Composites Produced Using Laser Powder Bed Fusion: A Review

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

The Effects of Reusing Cobalt-Chromium Alloy Powder on Its Mechanical Properties and Grain Size: An In Vitro Study

Contact Info

Product

Resources

About