This study examines how Laser Powder Bed Fusion (LPBF) process conditions can be employed to enable powder reuse while preserving powder quality, improving mechanical properties, and enhancing wear resistance, thereby addressing the high cost and the critical influence of metal powders on final performance. Laser power (280, 380, 480 W), number of recycles (5, 7, 9 cycles), and deposition thickness (35, 60, 85 μm) were varied to determine their effects on part properties and powder reusability. Ridge Regression and Random Forest machine learning models were used to effectively predict void nucleation, indentation modulus, and wear rate, enabling accurate process optimization. A Comparative analysis of two representative parameter combinations showed the individual contributions to wear performance. The findings revealed that the lowest void nucleation (1.94%), the minimum wear rate (0.97 × 10− 4 mm3/Nm), and the highest indentation modulus (115.15 GPa) were attained at an optimal combination of 380 W laser power, 35 μm deposition thickness, and seven powder reuse cycles. Wear mechanism analysis showed that the surface durability and wear resistance were enhanced by the formation of a protective layer of cladded AlSi10Mg particles formed during repeated reuse cycles. The study presents a statistical-based model that integrates experimental and predictive modelling strategies to optimise LPBF powder reuse, thereby improving material efficiency and demonstrating the feasibility of using reused AlSi10Mg powder in high-performance applications such as gearbox casings and internal automotive components.
Murugesan et al. (Fri,) studied this question.