Skip to main content
SpringerLink
Log in

Statistical approach for assessing the effect of powder reuse on the final quality of AlSi10Mg parts produced by laser powder bed fusion additive manufacturing

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The laser powder bed fusion (L-PBF) technique for metals is used in the field of additive manufacturing (AM) processes for the production of functional parts starting from metal powders. Due to the high cost of raw materials and the strong impact of their characteristics on the whole process, it leads essentially to exploit the possibility of reusing residual powder a certain number of times, while ensuring high part performances and productivity. This paper introduces the implementation of a statistical approach for assessing the effect of powder reuse on the mechanical properties and the surface quality of AlSi10Mg parts additively manufactured. Design of experiments (DOE) concepts and the pre-design guide sheets are used to define an accurate procedure and perform a reliable experimentation, while the one-way analysis of variance (ANOVA) and several graphical tools are used to analyse and summarise the experimental results. The effect of powder reuse showed statistical significance in terms of yield strength and ultimate tensile strength. Nonetheless, both the static and the cyclic mechanical properties of the produced samples exhibited small variability and compliance with the company specifications up to the last printing run.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Wang X, Gong X, Chou K (2017) Revier on powder-bed laser additive manufacturing of Inconel 718 parts. Proc Int Mech Eng Part B J Eng Manuf 231:1890–1903. https://doi.org/10.1177/0954405415619883

    Article  Google Scholar 

  2. Khairallah SA, Anderson AT, Rubenchik A, King WE (2016) Laser powder-bed fusion additive manufacturing: physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones. Acta Mater 108:36–45. https://doi.org/10.1016/j.actamat.2016.02.014

    Article  Google Scholar 

  3. ISO (2015) 17296-2:2015 additive manufacturing, general principles, part 2: overview of process categories and feedstock. International Organization for Standardization. ICS 25.030

  4. Herzog D, Seyda V, Wycisk E, Emmelmann C (2016) Additive manufacturing of metals. Acta Mater 117:371–392. https://doi.org/10.1016/j.actamat.2016.07.019

    Article  Google Scholar 

  5. Slotwinski JA (2013) Materials standards for additive manufacturing lecture, Engineering Lab. NIST. http://www.nist.gov/document/slotwinski-nist-am-materialspdf

  6. Slotwinski JA, Garboczi EJ, Stutzman PE, Ferraris CF, Watson SS, Peltz MA (2014) Characterization of metal powders used for additive manufacturing. J Res Natl Inst Stand Technol 119:460–493. https://doi.org/10.6028/jres.119.018

    Article  Google Scholar 

  7. Seyda V, Kaufmann N, Emmelmann C (2012) Investigation of aging processes of Ti-6Al-4V powder material in laser melting. Phys Procedia 39:425–431. https://doi.org/10.1016/j.phpro.2012.10.057

    Article  Google Scholar 

  8. Tang HP, Qian M, Liu N, Zhang XZ, Yang GY, Wang J (2015) Effect of powder reuse times on additive manufacturing of Ti-6Al-4V by selective electron beam melting. JOM 67:555–563. https://doi.org/10.1007/s11837-015-1300-4

    Article  Google Scholar 

  9. Ardila LC, Garciandia F, Gonzalez-Diaz JB, Alvarez P, Echeverria A, Petite MM, Deffley R, Ochoa J (2014) Effect of IN718 recycled powder reuse on properties of parts manufactured by means of selective laser melting. Phys Procedia 56:99–107. https://doi.org/10.1016/j.phpro.2014.08.152

    Article  Google Scholar 

  10. LPW Technology Ltd (2016) Case study 05: powder degradation. LPW Technology Ltd, Runcorn. www.lpwtechnology.com/wp-content/uploads/2016/09/LPW-Case-Study-05.pdf

    Google Scholar 

  11. Park SB, Road B (2016) White paper: investigating the effects of multiple re-use of Ti6Al4V powder in additive manufacturing. Renishaw Plc, Wotton-under-Edge. http://resources.renishaw.com/download.aspx?lang=en&data=83164&btn=1

    Google Scholar 

  12. Aboulkhair NT, Everitt NM, Ashcroft I, Tuck C (2014) Reducing porosity in AlSi10Mg parts processed by selective laser melting. Addit Manuf 1–4:77–86. https://doi.org/10.1016/j.addma.2014.08.001

    Article  Google Scholar 

  13. Palumbo B, Marrone R, De Chiara G (2009) Technological process innovation via engineering and statistical knowledge integration. In: Erto P (ed) Statistics for innovation. https://doi.org/10.1007/978-88-470-0815-1_10. Springer, Milan

  14. Palumbo B, Del Re F, Martorelli M, Lanzotti A, Corrado P (2017) Tensile properties characterization of AlSi10Mg parts produced by direct metal laser sintering via nested effects modeling. Materials 10(2):144. https://doi.org/10.3390/ma10020144

    Article  Google Scholar 

  15. Coleman DE, Montgomery DC (1993) A systematic approach to planning for a designed industrial experiment. Technometrics 35(1):25–27. https://doi.org/10.2307/1269285

    Google Scholar 

  16. ASTM (2015) B215-15 standard practices for sampling metal powders. ASTM International. https://doi.org/10.1520/B0215-15

  17. Cooke AL, Slotwinski JA (2012) Properties of metal powders for additive manufacturing: a review of the state of the art of metal powder property testing. CreateSpace Independent Publishing Platform, Gaithersburg. https://doi.org/10.6028/NIST.IR.7873

    Book  Google Scholar 

  18. ASTM (2017) B822-17 standard test method for particle size distribution of metal powders and related compounds by light scattering. ASTM International. https://doi.org/10.1520/B0822-17

  19. ASTM (2016) F1877-16 standard practice for characterization of particles. ASTM International. https://doi.org/10.1520/F1877-16

  20. ISO (2011) 3953:2011 metallic powders, determination of tap density. International Organization for Standardization. ICS 77.160

  21. ISO (2008) Standard 3923-1:2008 metallic powders, determination of apparent density, part 1: funnel method. International Organization for Standardization. ICS 77.160

  22. ASTM (2011) E34-11e1 standard test methods for chemical analysis of aluminum and aluminum-base alloys. ASTM International, https://doi.org/10.1520/E0034-11E01

  23. Frey M, Shellabear M, Thorsson L (2009) EOS whitepaper: mechanical testing of DMLS parts. EOS GmbH, Munich. http://gpiprototype.com/files/dmls/Whitepaper%20-%20Mechanical%20Testing%20of%20DMLS%20Parts.pdf

    Google Scholar 

  24. Mower TM, Long MJ (2016) Mechanical behavior of additive manufactured, powder-bed laser-fused materials. Mater Sci Eng A 651:198–213. https://doi.org/10.1016/j.msea.2015.10.068

    Article  Google Scholar 

  25. EN ISO (2016) Standard 6892-1:2016 metallic materials, tensile testing, part 1: method of test at room temperature. International Organization for Standardization. ICS 77.040.10

  26. ASTM (2016) E8/E8M-16a standard test methods for tension testing of metallic materials. ASTM International. https://doi.org/10.1520/E0008_E0008M-16A

  27. DIN EN (2011) 6072:2011 Aerospace series, metallic materials, test methods, constant amplitude fatigue testing. German institute for Standardization. www.beuth.de/en/standard/din-en-6072/140066421

  28. ASTM (2015) E466-15 standard practice for conducting force controlled constant amplitude axial fatigue tests of metallic materials. ASTM International. https://doi.org/10.1520/E0466-15 https://doi.org/10.1520/E0466-15

  29. ASTM (2015) E739-10 standard practice for statistical analysis of linear or linearized stress-life (S-N) and strain-life (-N) fatigue data. ASTM International. https://doi.org/10.1520/E0739-10

  30. ISO (1996) 4288:1996 geometrical product specifications (GPS)—surface texture: profile method—rules and procedures for the assessment of surface texture. International Organization for Standardization. ICS 17.140.20

  31. Montgomery DC (2005) Design and analysis of experiments. Wiley, Hoboken. ISBN 0-471-31649-0

    MATH  Google Scholar 

  32. Montgomery DC, Runger GC (2003) Applied statistics and probability for engineers. Wiley, Hoboken. ISBN 0-471-20454-4

    Google Scholar 

  33. Carpinteri A (1994) Handbook of fatigue crack propagation in metallic structures. Elsevier Science Publisher B.V., Amsterdam. ISBN 0-444-81645-3

    Google Scholar 

Download references

Acknowledgements

The authors are grateful to Giuseppe La Sala (IVL Department, MBDA), Daniela Di Martino (Radome Department, MBDA) and Michele Fornasiero (Additive Manufacturing specialist on behalf of Dragonfly company) for their detailed technological support in the pre-design and the experimental phases, as well as in the technological interpretation of the results.

Funding

The experimental activities presented above have been co-funded by Contratto di Programma Regionale per lo Sviluppo Innovativo delle Filere Manifatturiere Strategiche in Campania POR Campania FESR 2007-2013 Obiettivo Operativo 2.2 (Filiera Aerospazio, Iniziativa Wisch, Work Into Shaping Campania’s Home).

TECNEVA (TECNologie EVolutive per sistemi Avionici) Consortium was the proponent subject, 3F&EDIN S.p.A. the lead partner.

The activities were performed in collaboration with T2STAR (Tecnologie dei Sistemi per la Sicurezza Territoriale e AeRea) Consortium leaded by MBDA.

Author information

Authors and Affiliations

  1. Department of Industrial Engineering, University of Naples Federico II, P.le Tecchio 80, 80125, Naples, Italy

    F. Del Re & B. Palumbo

  2. Department of Chemical, Materials and Production Engineering, University of Naples Federico II, P.le Tecchio 80, 80125, Naples, Italy

    V. Contaldi, A. Astarita & A. Squillace

  3. MBDA Italia S.P.A., Via Calosi 105, 80070, Bacoli, Italy

    V. Contaldi, P. Corrado & P. Di Petta

Authors
  1. F. Del Re
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. V. Contaldi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. Astarita
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. B. Palumbo
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. A. Squillace
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. P. Corrado
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. P. Di Petta
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to F. Del Re.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Del Re, F., Contaldi, V., Astarita, A. et al. Statistical approach for assessing the effect of powder reuse on the final quality of AlSi10Mg parts produced by laser powder bed fusion additive manufacturing. Int J Adv Manuf Technol 97, 2231–2240 (2018). https://doi.org/10.1007/s00170-018-2090-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2090-y

Keywords

Search

Navigation