Effect of powder recycling on room and elevated temperature damage tolerability of Inconel 718 alloy fabricated by laser powder bed fusion

Inconel 718 (IN718) specimens were prepared by laser powder bed fusion (L-PBF) process using either virgin or recycled powder to investigate the effect of powder recycling on the damage tolerability (i.e., fracture toughness (KQ) and fatigue crack propagation (FCP)) at 25 and 650 °C. It was found that the KQ value of L-PBF IN718 specimen decreased marginally, while the FCP behavior was unaffected, with powder recycling at 25 and 650 °C. Detailed fractographic and micrographic analyses were conducted to identify the reason for two different trends in static and dynamic damage tolerability of L-PBF IN718 specimen made from virgin and recycled powder. •Damage tolerability of L-PBF IN718 specimens made from virgin and recycled power was assessed at 25 and 650 °C.•Fatigue crack propagation behavior of L-PBF IN718 was not sensitive to powder recycling at 25 and 650 °C.•Fracture toughness of L-PBF IN718 tended to decrease marginally with powder recycling at 25 and 650 °C.