Toward a sustainable laser powder bed fusion of Ti 6Al 4 V: Powder reuse and its effects on material properties during a single batch regime

Titanium alloy Ti6Al4V is the most used titanium alloy due to its high specific strength, ductility, corrosion resistance, and weldability. Currently, this alloy is produced with a density above 99% with laser welding-based additive manufacturing processes. However, the costs of titanium powder are high, and for critical components, the excess powder is usually not reused. In this work, we characterized the powder and additively manufactured Ti6Al4V parts by reusing the powder of a single batch to determine the impact on morphology, chemical composition, melt pool viscosity, density, microstructure, and tensile and impact strength. We aimed to determine the limits of powder reuse to increase sustainability and reduce the carbon footprint of Laser Powder Bed Fusion (L-PBF). We found that the powders pick up oxygen after each cycle to form an oxide layer up to 20 nm, causing a change in the optical and thermal properties of the titanium powders. This change affected the laser absorption and, with this, the melt pool properties. The powders reused after 18 cycles were responsible for a drop in the relative density of 0.1%. However, the tensile properties remained unchanged. The reused powders also presented a small shift in particle size distribution that did not affect the sphericity and increased flowability. In this work, we proved that the powders of Ti6Al4V alloys could be reused up to 18 cycles without any modification to the tensile properties but with a decrement in the impact strength of 30% for vertical- and 12% for horizontal stress-relieved specimens and 19% and 16% for furnace-annealed specimens, respectively.