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<p>In the recent past, powder bed fusion-laser beam (PBF-LB) has been used for fabricating high-performance/complex metallic components from primary recycled metallic powders. Previous studies have reported the reuse and recycling of 17-4 precipitate-hardened (PH) stainless steel (SS) primary recycled powder to enhance sustainability and cost efficiency in additive manufacturing (AM) with PBF-LB for a limited number of build cycles. However, little has been reported on the use of secondary recycled 17-4 PH SS mixed powder, possibly due to concerns about chemical inhomogeneity, intermetallic phase formation, and the resulting uncertainty in processability and mechanical performance during PBF-LB fabrication. In this study, the feasibility of using secondary recycled (mixed) powder comprising 17-4 PH SS and Ti-6Al-4&#xa0;V in the PBF-LB process, with particular emphasis on the potential influence of intermetallic formation in the fabricated components, was evaluated. The study also investigates the effect of scan strategy (SST) (rectangular, strip, and hexagonal) and infill topology (fully solid, Weariphelan (WP), and octet metastructures) on phase constitution, microstructural evolution, melt-pool behavior, solidification characteristics, and mechanical response of parts produced from secondary recycled powder and compares with virgin powder samples. Thermodynamic predictions (pseudo-binary phase diagrams) confirmed the formation of brittle intermetallic phases due to compositional inhomogeneity in the mixed powder, which limits the strain performance of the fabricated components compared to virgin 17-4 PH SS. The results suggest that samples fabricated with WP as the infill pattern (IP) in PBF-LB exhibited the lowest strain (~7.75%), whereas the IP solid/octet achieved ~ 10.1% strain.</p>

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Investigations on the Reusability of Secondary Recycled 17-4 Precipitate Hardened Stainless Steel by Powder Bed Fusion-Laser Beam

  • 期刊论文

  • 发表日期：

    2026年5月6日

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  • Ravinder Singh,
  • Rupinder Singh,
  • IPS Ahuja

摘要

In the recent past, powder bed fusion-laser beam (PBF-LB) has been used for fabricating high-performance/complex metallic components from primary recycled metallic powders. Previous studies have reported the reuse and recycling of 17-4 precipitate-hardened (PH) stainless steel (SS) primary recycled powder to enhance sustainability and cost efficiency in additive manufacturing (AM) with PBF-LB for a limited number of build cycles. However, little has been reported on the use of secondary recycled 17-4 PH SS mixed powder, possibly due to concerns about chemical inhomogeneity, intermetallic phase formation, and the resulting uncertainty in processability and mechanical performance during PBF-LB fabrication. In this study, the feasibility of using secondary recycled (mixed) powder comprising 17-4 PH SS and Ti-6Al-4 V in the PBF-LB process, with particular emphasis on the potential influence of intermetallic formation in the fabricated components, was evaluated. The study also investigates the effect of scan strategy (SST) (rectangular, strip, and hexagonal) and infill topology (fully solid, Weariphelan (WP), and octet metastructures) on phase constitution, microstructural evolution, melt-pool behavior, solidification characteristics, and mechanical response of parts produced from secondary recycled powder and compares with virgin powder samples. Thermodynamic predictions (pseudo-binary phase diagrams) confirmed the formation of brittle intermetallic phases due to compositional inhomogeneity in the mixed powder, which limits the strain performance of the fabricated components compared to virgin 17-4 PH SS. The results suggest that samples fabricated with WP as the infill pattern (IP) in PBF-LB exhibited the lowest strain (~7.75%), whereas the IP solid/octet achieved ~ 10.1% strain.