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<p>The laser powder bed fusion (LPBF) has recently been used to fabricate a rectangular wave guide (WR) with virgin metallic powder. However, little has been reported on using secondary (2°) recycled metallic powder for such applications. This study reports the fabrication of a circular wave guide (WC) using 2° recycled 17 − 4 precipitate hardened (PH) stainless steel (SS) powder with LPBF. For the recyclability of 2° recycled 17 − 4 PH SS powder, the used powder was preheated at 450&#xa0;°C for 01&#xa0;h. The WC were fabricated in vertical/ horizontal build orientations based on pre-print analysis, considering accumulated stress, heat, and boundary distortion. After printing, the samples were analyzed for variations in shell wall thickness (Δd), surface roughness (Ra) on inner contour, porosity%, grain size No. (G) and melt pool analysis. The results suggest that the vertical orientation has controlled Δd (mm) (+ 0.099/−0.00) than horizontal (+ 0.179/−0.00). However, in horizontal orientation, Ra and other surface characteristics (Ra: 10.97&#xa0;μm, porosity 14.34%, G 1.25) were observed better compared to vertical (Ra: 12.0&#xa0;μm, porosity 17.48%, G 0.5) at a fixed energy density (ED) of 71&#xa0;J/mm<sup>3</sup> using a hexagonal scanning strategy due to low outward Marangoni flow (2&#xa0;m/s) and less re-coil pressure.</p>

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On the Reusability of Secondary Recycled Powder for the Fabrication of Circular Waveguides

  • 期刊论文

  • 发表日期：

    2026年5月2日

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  • Bharat Kalia,
  • Rupinder Singh,
  • Kamaljit Singh Boparai

摘要

The laser powder bed fusion (LPBF) has recently been used to fabricate a rectangular wave guide (WR) with virgin metallic powder. However, little has been reported on using secondary (2°) recycled metallic powder for such applications. This study reports the fabrication of a circular wave guide (WC) using 2° recycled 17 − 4 precipitate hardened (PH) stainless steel (SS) powder with LPBF. For the recyclability of 2° recycled 17 − 4 PH SS powder, the used powder was preheated at 450 °C for 01 h. The WC were fabricated in vertical/ horizontal build orientations based on pre-print analysis, considering accumulated stress, heat, and boundary distortion. After printing, the samples were analyzed for variations in shell wall thickness (Δd), surface roughness (Ra) on inner contour, porosity%, grain size No. (G) and melt pool analysis. The results suggest that the vertical orientation has controlled Δd (mm) (+ 0.099/−0.00) than horizontal (+ 0.179/−0.00). However, in horizontal orientation, Ra and other surface characteristics (Ra: 10.97 μm, porosity 14.34%, G 1.25) were observed better compared to vertical (Ra: 12.0 μm, porosity 17.48%, G 0.5) at a fixed energy density (ED) of 71 J/mm3 using a hexagonal scanning strategy due to low outward Marangoni flow (2 m/s) and less re-coil pressure.