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The effect of powder recycling on the mechanical performance of laser powder bed fused stainless steel 316L

Rory Douglas, Nick Barnard, Nicholas Lavery Orcid Logo, James Sullivan Orcid Logo, Thomas Jones, Robert Lancaster Orcid Logo

Additive Manufacturing, Volume: 88, Start page: 104245

Swansea University Authors: Rory Douglas, Nick Barnard, Nicholas Lavery Orcid Logo, James Sullivan Orcid Logo, Robert Lancaster Orcid Logo

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DOI (Published version): 10.1016/j.addma.2024.104245

Abstract

Powder recycling refers to the reuse of unused powder feedstock in the laser powder bed fusion (PBF-LB/M) process. This approach is crucial for the economic viability and sustainability of PBF-LB/M, as powder accounts for a large proportion of the total production cost. However, through powder recyc...

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Published in: Additive Manufacturing
ISSN: 2214-8604
Published: Elsevier BV 2024
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URI: https://cronfa.swan.ac.uk/Record/cronfa66598
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This approach is crucial for the economic viability and sustainability of PBF-LB/M, as powder accounts for a large proportion of the total production cost. However, through powder recycling, the physical and chemical properties of powder are liable to change. This variation in powder properties can subsequently lead to knock-on effects on the mechanical properties of a fully built component.This research has investigated the changes that occur to stainless steel 316L (SS316L) powder as a result of recycling. This includes changes to powder size distribution (PSD), flowability, chemistry and phase composition. Likewise, the impact that these changes have will also be assessed in PBF-LB/M SS316L components manufactured from powders after different levels of recycling and subjected to alternative post processing routes such as hot isostatic pressing (HIP). This comprehensive investigation involves a thorough examination of both macro- and microstructures, encompassing detailed analyses of chemical composition, microstructural features, and defects. The study aims to elucidate differences in mechanical behaviour through a series of experiments, including uniaxial tensile tests, Charpy impact assessments, and low cycle fatigue (LCF) experiments. Additionally, the investigation will be complemented by pitting potential tests, providing a holistic understanding of the material's performance and characteristics.Although moderate changes to powder were observed for both PSD and chemistry, this was found to be negligible and not enough to result in any adverse changes to part performance. In addition, the microstructure of SS316L remained stable across differing levels of powder recycling. Whereas the porosity content increased marginally as the fine particle content of powder was reduced, this was not found to be sufficient to affect the LCF performance of the material. After powder recycling, increases in ductility and Young’s modulus were attributed to a reduction in oxides present in the microstructure, which were sources of localised damage and deformation.</abstract><type>Journal Article</type><journal>Additive Manufacturing</journal><volume>88</volume><journalNumber/><paginationStart>104245</paginationStart><paginationEnd/><publisher>Elsevier BV</publisher><placeOfPublication/><isbnPrint/><isbnElectronic/><issnPrint>2214-8604</issnPrint><issnElectronic/><keywords>Laser powder bed fusion; Powder recycling; Low cycle fatigue; Stainless steel 316L</keywords><publishedDay>25</publishedDay><publishedMonth>5</publishedMonth><publishedYear>2024</publishedYear><publishedDate>2024-05-25</publishedDate><doi>10.1016/j.addma.2024.104245</doi><url/><notes/><college>COLLEGE NANME</college><CollegeCode>COLLEGE CODE</CollegeCode><institution>Swansea University</institution><apcterm>SU Library paid the OA fee (TA Institutional Deal)</apcterm><funders>The current research was funded under the EPSRC Industrial Case Award EP/T517537/1. The provision of a research bursary, materials, and supporting information from Rolls-Royce plc. is gratefully acknowledged. Mechanical tests were performed at Swansea Materials Research and Testing Ltd. 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spelling v2 66598 2024-06-05 The effect of powder recycling on the mechanical performance of laser powder bed fused stainless steel 316L ce2bbab1ba034274ba6451ec8ae6cd8a Rory Douglas Rory Douglas true false dc4a58e614bc6a1d99812a3acfdd9034 Nick Barnard Nick Barnard true false 9f102ff59824fd4f7ce3d40144304395 0000-0003-0953-5936 Nicholas Lavery Nicholas Lavery true false 40e32d66748ab74184a31207ab145708 0000-0003-1018-773X James Sullivan James Sullivan true false e1a1b126acd3e4ff734691ec34967f29 0000-0002-1365-6944 Robert Lancaster Robert Lancaster true false 2024-06-05 Powder recycling refers to the reuse of unused powder feedstock in the laser powder bed fusion (PBF-LB/M) process. This approach is crucial for the economic viability and sustainability of PBF-LB/M, as powder accounts for a large proportion of the total production cost. However, through powder recycling, the physical and chemical properties of powder are liable to change. This variation in powder properties can subsequently lead to knock-on effects on the mechanical properties of a fully built component.This research has investigated the changes that occur to stainless steel 316L (SS316L) powder as a result of recycling. This includes changes to powder size distribution (PSD), flowability, chemistry and phase composition. Likewise, the impact that these changes have will also be assessed in PBF-LB/M SS316L components manufactured from powders after different levels of recycling and subjected to alternative post processing routes such as hot isostatic pressing (HIP). This comprehensive investigation involves a thorough examination of both macro- and microstructures, encompassing detailed analyses of chemical composition, microstructural features, and defects. The study aims to elucidate differences in mechanical behaviour through a series of experiments, including uniaxial tensile tests, Charpy impact assessments, and low cycle fatigue (LCF) experiments. Additionally, the investigation will be complemented by pitting potential tests, providing a holistic understanding of the material's performance and characteristics.Although moderate changes to powder were observed for both PSD and chemistry, this was found to be negligible and not enough to result in any adverse changes to part performance. In addition, the microstructure of SS316L remained stable across differing levels of powder recycling. Whereas the porosity content increased marginally as the fine particle content of powder was reduced, this was not found to be sufficient to affect the LCF performance of the material. After powder recycling, increases in ductility and Young’s modulus were attributed to a reduction in oxides present in the microstructure, which were sources of localised damage and deformation. Journal Article Additive Manufacturing 88 104245 Elsevier BV 2214-8604 Laser powder bed fusion; Powder recycling; Low cycle fatigue; Stainless steel 316L 25 5 2024 2024-05-25 10.1016/j.addma.2024.104245 COLLEGE NANME COLLEGE CODE Swansea University SU Library paid the OA fee (TA Institutional Deal) The current research was funded under the EPSRC Industrial Case Award EP/T517537/1. The provision of a research bursary, materials, and supporting information from Rolls-Royce plc. is gratefully acknowledged. Mechanical tests were performed at Swansea Materials Research and Testing Ltd. (SMaRT). 2024-06-13T12:02:19.8645187 2024-06-05T10:14:56.0644555 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering Rory Douglas 1 Nick Barnard 2 Nicholas Lavery 0000-0003-0953-5936 3 James Sullivan 0000-0003-1018-773X 4 Thomas Jones 5 Robert Lancaster 0000-0002-1365-6944 6 66598__30628__4907fc2fa8394917b5a5ffd9975843f8.pdf 66598.VoR.pdf 2024-06-13T11:57:29.4507149 Output 19272540 application/pdf Version of Record true © 2024 The Authors. This is an open access article under the CC BY license. true eng http://creativecommons.org/licenses/by/4.0/
title The effect of powder recycling on the mechanical performance of laser powder bed fused stainless steel 316L
spellingShingle The effect of powder recycling on the mechanical performance of laser powder bed fused stainless steel 316L
Rory Douglas
Nick Barnard
Nicholas Lavery
James Sullivan
Robert Lancaster
title_short The effect of powder recycling on the mechanical performance of laser powder bed fused stainless steel 316L
title_full The effect of powder recycling on the mechanical performance of laser powder bed fused stainless steel 316L
title_fullStr The effect of powder recycling on the mechanical performance of laser powder bed fused stainless steel 316L
title_full_unstemmed The effect of powder recycling on the mechanical performance of laser powder bed fused stainless steel 316L
title_sort The effect of powder recycling on the mechanical performance of laser powder bed fused stainless steel 316L
author_id_str_mv ce2bbab1ba034274ba6451ec8ae6cd8a
dc4a58e614bc6a1d99812a3acfdd9034
9f102ff59824fd4f7ce3d40144304395
40e32d66748ab74184a31207ab145708
e1a1b126acd3e4ff734691ec34967f29
author_id_fullname_str_mv ce2bbab1ba034274ba6451ec8ae6cd8a_***_Rory Douglas
dc4a58e614bc6a1d99812a3acfdd9034_***_Nick Barnard
9f102ff59824fd4f7ce3d40144304395_***_Nicholas Lavery
40e32d66748ab74184a31207ab145708_***_James Sullivan
e1a1b126acd3e4ff734691ec34967f29_***_Robert Lancaster
author Rory Douglas
Nick Barnard
Nicholas Lavery
James Sullivan
Robert Lancaster
author2 Rory Douglas
Nick Barnard
Nicholas Lavery
James Sullivan
Thomas Jones
Robert Lancaster
format Journal article
container_title Additive Manufacturing
container_volume 88
container_start_page 104245
publishDate 2024
institution Swansea University
issn 2214-8604
doi_str_mv 10.1016/j.addma.2024.104245
publisher Elsevier BV
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 1
active_str 0
description Powder recycling refers to the reuse of unused powder feedstock in the laser powder bed fusion (PBF-LB/M) process. This approach is crucial for the economic viability and sustainability of PBF-LB/M, as powder accounts for a large proportion of the total production cost. However, through powder recycling, the physical and chemical properties of powder are liable to change. This variation in powder properties can subsequently lead to knock-on effects on the mechanical properties of a fully built component.This research has investigated the changes that occur to stainless steel 316L (SS316L) powder as a result of recycling. This includes changes to powder size distribution (PSD), flowability, chemistry and phase composition. Likewise, the impact that these changes have will also be assessed in PBF-LB/M SS316L components manufactured from powders after different levels of recycling and subjected to alternative post processing routes such as hot isostatic pressing (HIP). This comprehensive investigation involves a thorough examination of both macro- and microstructures, encompassing detailed analyses of chemical composition, microstructural features, and defects. The study aims to elucidate differences in mechanical behaviour through a series of experiments, including uniaxial tensile tests, Charpy impact assessments, and low cycle fatigue (LCF) experiments. Additionally, the investigation will be complemented by pitting potential tests, providing a holistic understanding of the material's performance and characteristics.Although moderate changes to powder were observed for both PSD and chemistry, this was found to be negligible and not enough to result in any adverse changes to part performance. In addition, the microstructure of SS316L remained stable across differing levels of powder recycling. Whereas the porosity content increased marginally as the fine particle content of powder was reduced, this was not found to be sufficient to affect the LCF performance of the material. After powder recycling, increases in ductility and Young’s modulus were attributed to a reduction in oxides present in the microstructure, which were sources of localised damage and deformation.
published_date 2024-05-25T12:02:19Z
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score 11.016235

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