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<p>Laser powder bed fusion (LPBF) of Ti–6Al–4V relies critically on powder quality, which degrades with repeated reuse. This study presents a comparative analysis of fresh powder-equivalent 1× reused, 20× reused, and refurbished (spheroidized) powders to quantify morphological and compositional evolution. Emphasis is placed on particle size distribution (PSD), particle morphology, and oxygen content as key indicators of degradation and restoration. Progressive reuse leads to increased oxygen pickup, particle coarsening, and reduced sphericity, adversely affecting flowability and spreadability. Refurbished powder demonstrates partial to near-complete recovery of PSD and morphology, along with reduced oxygen levels. These results establish a quantitative framework for assessing powder degradation and the effectiveness of refurbishment in restoring LPBF feedstock quality.</p> Graphical abstract <p></p>

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Circular supply chain framework for refurbished Ti–6Al–4V powder for laser powder bed fusion

  • 期刊论文

  • 发表日期：

    2026年4月24日

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  • Ankita Roy,
  • Yash Parikh

摘要

Laser powder bed fusion (LPBF) of Ti–6Al–4V relies critically on powder quality, which degrades with repeated reuse. This study presents a comparative analysis of fresh powder-equivalent 1× reused, 20× reused, and refurbished (spheroidized) powders to quantify morphological and compositional evolution. Emphasis is placed on particle size distribution (PSD), particle morphology, and oxygen content as key indicators of degradation and restoration. Progressive reuse leads to increased oxygen pickup, particle coarsening, and reduced sphericity, adversely affecting flowability and spreadability. Refurbished powder demonstrates partial to near-complete recovery of PSD and morphology, along with reduced oxygen levels. These results establish a quantitative framework for assessing powder degradation and the effectiveness of refurbishment in restoring LPBF feedstock quality.

Graphical abstract