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Metal additive manufacturing (AM) is being rapidly adopted in the aerospace and biomedical industries. Powder bed fusion AM processes are leading this trend. To maximize process economy, excess ''unmelted'' powder retrieved from the build chamber is used in subsequent build cycles. The metal properties and component reliability could undergo degradation with powder reuse. This study investigates the effects of powder reuse on fracture surface characteristics of Ti6Al4V specimens fabricated by electron beam melting AM over 30 sequential build cycles. Optical microscopy and scanning electron microscopy were used to evaluate the changes in fracture surface features of tensile failures with powder reuse. Macroscopically, slant fractures were most common in early builds, which transitioned to orthogonal fracture surfaces with poorly defined shear lips with increasing reuse. Regardless of the build number, the fracture origins were consistently from the as-built surfaces. Microscopically, ductile features such as micro-void coalescence were evident throughout the 30 build cycles. However, increasing flute content with reuse suggests that rising oxygen levels causes solution strengthening and limits the participation of active slip systems. These results highlight the importance of surface roughness and powder oxidation to metal performance in AM, and the evolution of fractographic features with powder reuse.

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