The Role of Powder Feedstock in Directed Energy Deposition Sustainability

Abstract

In this paper, preliminary results on the feasibility of reusing unmelted feedstock material in powder-blown laser Directed Energy Deposition are reported. The environmental impact assessment and sustainability aspects of laser Directed Energy Deposition are also illustrated. Inconel 625 powder was used and cuboids samples were deposited on stainless steel 316 substrate. The unmelted powder was collected and characterized and then reused four times to build samples for five cycles of deposition, without the addition of more virgin powder. Promising results toward the adoption of powder reuse in laser Directed Energy Deposition processes, in terms of powder physical and chemical characteristics, were obtained. The environmental impact analysis highlighted that powder reuse will generate significant savings that will contribute to the sustainability of the laser Directed Energy Deposition process.