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Recycling of Stainless Steel Milling Chips for Additive Manufacturing: A Three-Stage Comminution Approach Using a Fine Impact Mill
- The production of conventional metal powders for additive manufacturing process is energy intensive and costly. This study introduces a sustainable alternative by recycling stainless steel milling chips as feedstock for laser-powder directed energy deposition. The recycling process employs a three-stage mechanical comminution method utilizing a fine impact mill UPZ100 from Hosokawa Alpine AG. Characterization of the resulting powders is conducted through particle morphology analysis, flowability tests, and mechanical property assessments. The chip-derived powders exhibit comparable aspect ratios and sphericity to conventional water atomized powders, though with reduced flowability due to a pronounced fine fraction content. Elevated levels of oxides are observed, leading to the formation of an oxide layer on specimen blocks, without impairing the mechanical properties. Analyses of porosity, microstructure, and hardness indicate no significant differences when compared to conventionalThe production of conventional metal powders for additive manufacturing process is energy intensive and costly. This study introduces a sustainable alternative by recycling stainless steel milling chips as feedstock for laser-powder directed energy deposition. The recycling process employs a three-stage mechanical comminution method utilizing a fine impact mill UPZ100 from Hosokawa Alpine AG. Characterization of the resulting powders is conducted through particle morphology analysis, flowability tests, and mechanical property assessments. The chip-derived powders exhibit comparable aspect ratios and sphericity to conventional water atomized powders, though with reduced flowability due to a pronounced fine fraction content. Elevated levels of oxides are observed, leading to the formation of an oxide layer on specimen blocks, without impairing the mechanical properties. Analyses of porosity, microstructure, and hardness indicate no significant differences when compared to conventional powders from water or gas atomization. This recycling approach not only mitigates waste but also enhances the potential for a circular and sustainable manufacturing process in the additive manufacturing industry and beyond.…


| Autor*innen: | Vinzenz Müller, Oliver Klement, Steffen Sander, Max Biegler, Michael RethmeierORCiD |
|---|---|
| Dokumenttyp: | Zeitschriftenartikel |
| Veröffentlichungsform: | Verlagsliteratur |
| Sprache: | Englisch |
| Titel des übergeordneten Werkes (Englisch): | IOP Conference Series: Materials Science and Engineering |
| Jahr der Erstveröffentlichung: | 2025 |
| Organisationseinheit der BAM: | 9 Komponentensicherheit |
| 9 Komponentensicherheit / 9.3 Schweißtechnische Fertigungsverfahren | |
| Veröffentlichende Institution: | Bundesanstalt für Materialforschung und -prüfung (BAM) |
| Verlag: | IOP Publishing |
| Jahrgang/Band: | 1332 |
| Ausgabe/Heft: | 1 |
| Aufsatznummer: | 012014 |
| Erste Seite: | 1 |
| Letzte Seite: | 7 |
| DDC-Klassifikation: | Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten |
| Freie Schlagwörter: | Comminution; Directed Energy Deposition; Powder characteristics; Recycling; Stainless steel |
| Themenfelder/Aktivitätsfelder der BAM: | Material |
| Material / Additive Fertigung | |
| DOI: | 10.1088/1757-899X/1332/1/012014 |
| URN: | urn:nbn:de:kobv:b43-652037 |
| ISSN: | 1757-8981 |
| Verfügbarkeit des Dokuments: | Datei für die Öffentlichkeit verfügbar ("Open Access") |
| Lizenz (Deutsch): | Creative Commons - CC BY - Namensnennung 4.0 International |
| Datum der Freischaltung: | 22.12.2025 |
| Referierte Publikation: | Nein |
| Schriftenreihen ohne Nummerierung: | Wissenschaftliche Artikel der BAM |


