Comparison between Virgin and Recycled 316L SS and AlSi10Mg Powders Used for Laser Powder Bed Fusion Additive Manufacturing

In this study, the comparison of properties between fresh (virgin) and used (recycled) 316L stainless steel (316L SS) and AlSi10Mg powders for the laser powder bed fusion additive manufacturing (L-PBF AM) process has been investigated in detail. Scanning electron microscopy (SEM), electron-dispersive X-ray spectroscopy (EDX), and X-ray diffraction (XRD) techniques are used to determine and evaluate the evolution of morphology, particle size distribution (PSD), circularity, chemical composition, and phase (crystal structure) in the virgin and recycled powders of both materials. The results indicate that both recycled powders increase the average particle sizes and shift the PSD to higher values, compared with their virgin powders. The recycled 316L SS powder particles largely retain their spherical and near-spherical morphologies, whereas more irregularly shaped morphologies are observed for the recycled AlSi10Mg counterpart. The average circularity of recycled 316L SS powder only reduces by similar to 2%, but decreases similar to 17% for the recycled AlSi10Mg powder. EDX analysis confirms that both recycled powders retain their alloy-specific chemical compositions, but with increased oxygen content. XRD spectra peak analysis suggests that there are no phase change and no presence of any undesired precipitates in both recycled powders. Based on qualitative comparative analysis between the current results and from various available literature, the reuse of both recycled powders is acceptable up to 30 times, but re-evaluation through physical and chemical characterizations of the powders is advised, if they are to be subjected for further reuse.