Investigation On Reusability Of Plasma-atomized Aluminum Powder During L-PBF

Plasma-atomized AlSi10Mg powder was processed using L-PBF technology up to fifteen build cycles. Starting with virgin material the powder was successive processed and exposed to the AM process. For comparison two different reuse strategies were conducted: no refreshing and frequent refreshing with virgin powder. Samples from different build cycles were characterized for porosity and for mechanical properties such as tensile and fatigue. In parallel to these tests the oxygen and nitrogen content of both: the consolidated material and the corresponding powder was measured. All data from powder feedstock and printed parts was captured using a novel approach for powder lifecycle management. The material showed consistent or even improved performance under static and dynamic load over the entire study. No decrease in fatigue lifetime was detected.