An all-encompassing study on the joint effect of powder feedstock characteristics and manufacturing process parameters on the densification and mechanical properties of additively manufactured nickel alloy 718

Laser-powder bed fusion (L-PBF) is a commonly employed additive manufacturing (AM) technique in manu-facturing 3D metallic parts with complex geometries from powder materials. It is a complex process with more than 100 process parameters affecting the properties of fabricated parts. Studies on AM of nickel alloy 718 are currently focusing on investigating the effect of the process parameters and heat treatment on final part properties. Nevertheless, the effect of different powder characteristics such as particle size distribution (PSD), the presence of fine particles, powder reuse, and moisture content has not been studied comprehensively in the literature. In this study, two types of powder: virgin and recycled, as well as four parameters: PSD, which is represented by the median particle size and the particle size range, moisture content, and volumetric energy density (VED), were studied. To reduce experimental cost and burden, statistical design of experiment (DOE) techniques were utilized. Then, the measured results were analyzed using analysis of variance (ANOVA) to ascertain the effect of the different powder characteristics on multiple quantities of interest (QoIs). Different densification and mechanical tests were performed, and their outputs were studied as the QoIs. This study revealed that VED, powder type, PSD range, and median are the most common significant factors for most QoIs. Meanwhile, moisture content had a significant effect only on the Charpy impact energy. Besides, the study showed that the presence of fine particles < 20 mu m improved the densification of the fabricated parts but reduced the mechanical properties.