Metal powder atomization preparation, modification, and reuse for additive manufacturing: A review

Additive manufacturing (AM) processes are pivotal in various manufacturing industries due to their efficiency and ability to produce parts with complex structures and shapes. Metal powders, essential as feedstock for AM, especially in direct energy deposition (DED) and powder bed fusion (PBF) processes, have garnered significant attention from academia and industry. However, a comprehensive review focusing on the entire lifecycle of powders for AM is currently lacking. This review provides an exhaustive overview of powders used in AM, covering powder preparation methods, modification, and reuse. We critically discuss and compare various powder preparation techniques and review their properties, characterization methods, and impacts on AM processes. Here, we also summarize powder modification methods and improvements in powder properties and AM-produced parts. Finally, we address the reuse of powders in AM fabrication, including strategies, effects, and assessments of reusability post-manufacturing, which are crucial for reducing AM-associated costs. This work offers a state-of-the-art perspective in preparation, modification, and reuse of metal powders in AM.