Reuse potential of recycled powder for additive manufacturing of AlSi10Mg alloy for corrosion resistant applications

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To increase widespread implementation of additive manufacturing in many industries, improving cost**affordability of this state of the art manufacturing technology, while maintaining the part's quality, is crucial.**Additive Metal Manufacturing Inc. (AMM), the industrial partner, has been investigating an innovative idea of**separating partially melted or condensate powder from the unmelted powder through a sieving operation,**collected during the direct metal laser sintering (DMLS) process, and reusing this recycled powder again as the**feedstock powder for further manufacturing. However, the number of permitted powder reuse cycles without**adversely affecting the properties of the printed component is still unknown to AMM. This knowledge is very**crucial in producing high-quality parts with consistent properties particularly for harsh environment**applications, such as in marine and aerospace, in which high corrosion resistivity of the component, quality**control, and standardization are critical requirements. In this project, the impact of powder reuse times on**corrosion resistance and integrity of the DMLS fabricated AlSi10Mg_200C parts produced from recycled**powders versus its virgin powder fabricated counterpart in a simulated marine environment will be investigated**by our research team. This project aims to enhance the competitiveness of metal additive manufacturing**technology in Canada with advanced, innovative, and fast powder bed technologies. In addition, this project**will help AMM and other manufacturer in Canada to adopt greener manufacturing practices in accordance with**Government of Canada mandate on lowering carbon footprint through the use of recycled powders in additive**manufacturing of lighter metals.