Metal Powders In Additive Manufacturing: An Approach To Sustainable Production And Recycling

Gas atomization is the primary technique to produce powders used in metal additive manufacturing. The size of gas atomized powders typically ranges from 1 to 150 µm. However, for laser bed powder fusion (LBPF), mainly powders within the 20-63 µm range are used. Consequently, recycling powders that fall outside this specification presents significant opportunities for creating a more sustainable and environmentally friendly supply chain. Reprocessing these out-of-specification powders can reduce waste, lower production costs, and minimize the environmental impact associated with the extraction and processing of raw materials.Two recycling routes are explored in this study. The first involves transforming fine powders (14?µm) into ingots using the casting process Plasma Arc Melting - Cold Hearth Refining (PAM-CHR), followed by a re-atomization with the Electrode Induction Melting Gas Atomization (EIGA) process. The second route recycles coarse powders (>63?µm) directly using the Vacuum Induction Melting Gas Atomization (VIGA) process. These approaches enhance resource