2026 Warner AlSi7Mg Reused Powder Heat Treatment

Laser powder bed fusion produces parts with low material waste, but the reuse of powder can alter the properties of additively manufactured components. This study aimed to evaluate the efficacy of a T6 heat treatment to minimize the adverse effects of powder reuse on the mechanical properties of AlSi7Mg throughout up to 20 build cycles. To this end, a refreshing powder reuse technique was employed, wherein parts were either stress relieved or T6 treated. The effect of these heat treatments on the mechanical properties was assessed. Results indicated that while minimal alterations in part microstructures were observed, stress-relieved samples exhibited an increase in hardness by 6.0% and tensile strength by 7.2% over the first seven and nine manufacturing runs, respectively. Other properties like yield strength, ductility, and flexural properties remained stable. In contrast, T6-treated samples showed no significant changes in these properties throughout the powder reuse cycles. The findings suggest that heat treatment strategies, particularly T6 treatment, can effectively mitigate the negative impacts associated with powder reuse in additive manufacturing, thereby ensuring consistent material performance.