Evaluation of recycling strategies for SS316L powder in laser powder bed fusion: impacts on mechanical properties and fatigue performance

The present article encapsulates the essence of exploring the consequences of employing recycled SS 316L powder in laser powder bed fusion (LPBF) metal additive manufacturing (MAM), although the implementation of the as-built AM parts into essential safety applications (i.e., under cyclic performance) is difficult due to the surface finish and thereby mechanical properties of the components. In addition, the partial melting of powder contributes to surface integrity in the bi-direction (i.e., transverse and longitudinal), leading to the necessity for improvement and standardization of recycling/reusing the powders that further reduce the economic viability. Through systematic review, the present article aims to provide insights into the implications of powder recycling on the mechanical properties, structural integrity, and performance reliability of LPBF-printed parts. Furthermore, strategies for mitigating potential drawbacks associated with recycled powder usage, such as process parameter optimization and implementation of quality control measures, are discussed. Recycled powder properties are influenced by properties such as microstructure, porosity, and mechanical properties. The findings contribute to a comprehensive understanding of the trade-offs involved in reuse strategies for recycled SS 316L powder in LPBF-AM, thereby informing future research directions and industrial practices aimed at enhancing the sustainability, durability, and performance of MAM processes.