The impact of powder reuse on powder characteristics of laser powder bed fusion TA 15 alloy

Purpose Most research on Laser powder bed fusion (L-PBF) has focused on using virgin metal powders. Meanwhile, the microstructure and mechanical properties of annealed L-PBF components produced with reused powders, particularly titanium alloys, have been less thoroughly investigated. This study aims to understand the characteristics of TA15 reused powder and its effect on the properties of L-PBF alloy. Design/methodology/approach This study evaluated the powder properties, porosity, surface morphology and tensile properties of annealed titanium alloy TA15 fabricated with virgin powder and powders after the 3rd and 6rd reuse cycles (referred to as 0, 3 and 6 cycles, respectively). The powder characteristics after different reuse cycles were analyzed to understand their effect on the annealed alloy. Findings Results showed that particle size changed slightly with increasing reuse cycles, while the proportion of hollow particles remained stable. Many irregular pores were found in the hollow particles, and significant changes in C, N and O contents were noted. In terms of tensile properties, the strength of the annealed alloy increased while plasticity decreased with additional reuse cycles. In addition, the hardness of the annealed specimens’ side (parallel to the building direction) initially increased and then slightly decreased. Originality/value The results provide a reference for powder reuse and mechanical properties of L-PBF TA 15 alloy.