The effects of powder reuse on the mechanical response of electron beam additively manufactured Ti6Al4V parts

Soundarapandiyan, Gowtham; Johnston, Carol; Khan, Raja H.U.; Leung, Chu Lun Alex; Lee, Peter; Hernández-Nava, Everth; Chen, Bin; Fitzpatrick, Michael E.

doi:10.1016/j.addma.2021.102101

Cited by 14 publications

(7 citation statements)

References 51 publications

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“…The strengthening of Ti6Al4V is linked to the elevation of oxygen in an interstitial solid solution. However, the decrease in ductility reported here seems to be more pronounced than in other studies [ 24 , 25 ]. However, it should be noted that our work reports reduction in area, whereas the work of others reports on percent elongation.…”

Section: Discussioncontrasting

confidence: 86%

Powder Reuse in Laser-Based Powder Bed Fusion of Ti6Al4V—Changes in Mechanical Properties during a Powder Top-Up Regime

Harkin

Nikam

et al. 2022

Materials

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The properties of Extra Low Interstitials (ELI) Ti6Al4V components fabricated via the laser-based powder bed fusion (L-PBF) process are prone to variation, particularly throughout a powder reuse regime. Interstitial pick-up of interstitial elements within the build chamber during processing can occur, most notably, oxygen, nitrogen, and hydrogen, which can impair the mechanical properties of the built component. This study analyses ELI Ti6Al4V components manufactured by the L-PBF process when subjected to a nine-stage powder reuse sequence. Mechanical properties are reported via hardness measurement and tensile testing. Results showed that from 0.099 wt.% to 0.126 wt.% oxygen content, the mean hardness and tensile strength increased from 367.8 HV to 381.9 HV and from 947.6 Mpa to 1030.7 Mpa, respectively, whereas the ductility (area reduction) reduced from around 10% to 3%. Statistical analysis based on the empirical model from Tabor was performed to determine the strength–hardness relationship. Results revealed a significant direct relationship between tensile strength and Vickers hardness with a proportionality constant of 2.61 (R-square of 0.996 and p-value of 6.57 × 10−6).

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Section: Discussioncontrasting

confidence: 86%

Powder Reuse in Laser-Based Powder Bed Fusion of Ti6Al4V—Changes in Mechanical Properties during a Powder Top-Up Regime

Harkin

Nikam

et al. 2022

Materials

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“…As more research results emerge, researchers have found that the uniform distribution of nano-oxides can be achieved by controlling the number, size and distribution of oxide inclusions in steel (for example by SEBM technology with instantaneous melting and rapid solidification characteristics), which helps to improve the performance of parts. Soundarapandiyan et al [24] found that the yield strength and tensile strength of Ti6Al4V parts increased with the increase of powder oxygen content. Since the SEBM build process maintains high preheat and forming temperatures, the solid part and the powder surface form oxide and deepen the oxide layer thickness.…”

Section: Resultsmentioning

confidence: 99%

Effect of reuse times on H13 powder properties processed by selective electron beam melting

et al. 2022

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The inconsistency of high material cost and powder properties are the primary barriers to widespread adoption of metal additive manufacturing. Obviously, powder reuse without affecting the properties of the parts can reduce the cost burden. In this study, the properties of H13 (4Cr5MoSiV1) powder were evaluated 16 build cycles in selective electron beam melting. Results show that the crystal plane spacing and particle size of the powder increased with reuse. With the increase i reuse times, more irregular particles appeared and the flowability decreased. The oxygen and nitrogen content of powder gradually increases from 149 to 250 ppm and 237 ppm to 394 ppm, respectively, with reuse. The simulation results show that the wider particle size distribution, the better the relative packing performance of the powder layer. Powder reuse has no negative effect on the hardness of the as-built samples.

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“…Recent studies have shown that particle size distribution PSD became narrower after reuse cycles, indicating a decrease in the proportion of ne particles involved in the melting process, followed by a drop in the quantity of larger particles, which were reduced progressively by the sieve device after reuse [7-9, 12, 14, 20, 24, 25]. Soundarapandiyan [13] and Richard and O'Leary [7] con rmed our ndings by reporting the same behavior of the Ti-6Al-4V powder PSD, which shifted rightward after ve reuse cycles. Furthermore, Sutton et al [17] found comparable results using AISI 304L stainless steel powder, demonstrating an increase in particle size after ve printing cycles.…”

Section: Discussionmentioning

confidence: 99%

“…Several researchers have recently studied the effect of reusing powder on chemical and physical powder characteristics and the mechanical performance of components produced with L-PBF and EBM technologies for different materials, such as titanium Ti-6Al-4V [4,[8][9][10][11][12][13][14], stainless steel [15][16][17][18][19],…”

Section: Introductionmentioning

confidence: 99%

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Maraging steel powder recycling effect on the tensile and fatigue behavior of parts produced through the laser powder bed fusion (L-PBF) process

Rayan

Brousseau

Belzile

et al. 2023

Int J Adv Manuf Technol

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Additive manufacturing (AM) has advanced the manufacturing industry and has been employed in a wide range of industrial applications, including in aerospace, automotive, medical and die-casting equipment. To ensure the cost-effectiveness of the AM process, unfused powder must be recycled even if its characteristics may change after each cycle, making essential the validation of powder quality and component mechanical performances. Despite the research published to date, predicting the mechanical performance of printed parts issued from reused powder remains challenging since it is dependent on many AM process variables. Until now, no research has looked at the impact of powder recycling on the fatigue behavior of maraging steel components. This study investigates the impact of maraging steel powder reuse on powder characteristics, as well as on the tensile and fatigue properties of printed components. Our results indicate that the powder particle size distribution increased after eight powder recycling, particle morphology showed the presence of aggregates, broken particles, shattered and deformed particles, while powder apparent density remained constant. Powder reusing had no signi cant impact on the surface roughness of as-built specimens. Although there was a slight decrease in mechanical properties over reuse cycles, tensile and fatigue performance remained globally stable, while the standard deviation of fatigue stress became narrower after eight cycles. Finally, fractography revealed that the fatigue fracture surfaces of components manufactured from an eight-time recycled powder have more fusion defects and carbon inclusions than the parts made from virgin powder.

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The effects of powder reuse on the mechanical response of electron beam additively manufactured Ti6Al4V parts

Cited by 14 publications

References 51 publications

Powder Reuse in Laser-Based Powder Bed Fusion of Ti6Al4V—Changes in Mechanical Properties during a Powder Top-Up Regime

Powder Reuse in Laser-Based Powder Bed Fusion of Ti6Al4V—Changes in Mechanical Properties during a Powder Top-Up Regime

Effect of reuse times on H13 powder properties processed by selective electron beam melting

Maraging steel powder recycling effect on the tensile and fatigue behavior of parts produced through the laser powder bed fusion (L-PBF) process

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