Parametrization and characterization of DED printings using recycled AISI 303 powder particles

• Published in: Powder technology Vol. 435; p. 119453
• Main Authors: Castanheira, Lara, Gil, Jorge, Amaral, Rui, Vieira, Teresa, Reis, Ana, Emadinia, Omid
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 15.02.2024
• Subjects: Mechanical properties; Microstructure characterizations; Milling; Powder characteristics; Printing optimization; Upcycling metal chips; Mechanical properties; Printing optimization; Upcycling metal chips; Powder characteristics; Milling; Microstructure characterizations
• ISSN: 0032-5910; 1873-328X
• DOI: 10.1016/j.powtec.2024.119453

This study investigates an upcycling solution to transform AISI 303 stainless steel chips into powder feedstock for Direct Energy Deposition (DED) printing. All the chips were transformed into particles, using a disc milling process, in a size range of 38 to 212 μm with irregular shapes. The work proceeded by parametrizing DED printings on a non-preheated AISI 1045 substrate. Then, a wall-like structure was printed and submitted to microstructure, tomography, microhardness, tensile test and fracture analyses. The printed alloy showed a hardness of 220 ± 14 HV0.1 with a reducing tendency from the heat-affected zone to the topmost region, attributed to the formation of oxides and heat accumulation. The bimetallic specimen tensile test showed failure in the substrate region, verifying a good bonding of the interface. Tomography analysis also validated this result. [Display omitted] •Transformation of AISI 303 chips into powder feedstock in an optimized efficiency.•Chemical composition, shape, size distribution, density and flowability of powders.•Successful printing of angular particles with a large particle size distribution.•Defect free and strong joint of a printed alloy on a dissimilar substrate.