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By using additive manufacturing techniques like the laser powder bed fusion (LPBF) process, parts can be manufactured with high material efficiency because unfused powder material can be reconditioned and reused in consecutive manufacturing jobs. Nevertheless, process by-products like spatters may influence the powder quality and hence alter the mechanical properties/performance of parts. In order to investigate these dependencies, a methodology and a standard build job for the recycling behavior of the lightweight aluminum alloy AlSi10Mg was developed and built with ageing powder in 10 consecutive jobs with no refreshing between the cycles. The powder properties and mechanical performance of parts at static load for two build directions (horizontally and vertically to substrate plate) was evaluated. The influence of build height effects on mechanical performance was investigated as well. The findings may indicate that the coarsening of the powder material during recycling could lead to improved mechanical properties for the AlSi10Mg alloy.

On the Influence of AlSi10Mg Powder Recycling Behavior in the LPBF Process and Consequences for Mechanical Properties