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Influence of Haynes 282 powder oxidation on powder properties and component quality in laser powder bed fusion

  • Reuse of powder in powder bed additive manufacturing is a common practice to enhance sustainability and reduce costs. However, the reusability of metal powder is limited by the oxidation of the powders. Even in a protective atmosphere, each build job leads to gradual oxidation of the powder, which has led to concerns about its impact on powder and part properties. Consequently, strict confidence intervals for oxygen content in nickel-based alloy feedstocks are enforced in the industry. Despite this, there is currently a lack of in-depth studies investigating the specific influence of oxygen on Haynes 282, a widely used nickel-based alloy. This study examines artificially aged Haynes 282 powder batches with oxygen content of 160 ppm, 330 ppm, 1050 ppm, and 1420 ppm. Detailed powder characterization was performed, including morphology, chemical composition, particle size, flowability, and packing behavior. Components were fabricated via PBF-LB/M to evaluate density and mechanicalReuse of powder in powder bed additive manufacturing is a common practice to enhance sustainability and reduce costs. However, the reusability of metal powder is limited by the oxidation of the powders. Even in a protective atmosphere, each build job leads to gradual oxidation of the powder, which has led to concerns about its impact on powder and part properties. Consequently, strict confidence intervals for oxygen content in nickel-based alloy feedstocks are enforced in the industry. Despite this, there is currently a lack of in-depth studies investigating the specific influence of oxygen on Haynes 282, a widely used nickel-based alloy. This study examines artificially aged Haynes 282 powder batches with oxygen content of 160 ppm, 330 ppm, 1050 ppm, and 1420 ppm. Detailed powder characterization was performed, including morphology, chemical composition, particle size, flowability, and packing behavior. Components were fabricated via PBF-LB/M to evaluate density and mechanical properties. The results showed that higher oxidation levels improved powder flowability and packing density. However, in manufactured parts, irregular melt tracks and increased surface roughness were observed, which could easily be removed by post-processing. No significant differences in density or mechanical properties at room temperature, such as tensile strength and elongation, were found. These findings indicate that H282 powder potentially remains suitable for reuse, even when the batches exhibit increased oxygen content, supporting discussions on revising the existing oxygen content confidence intervals for nickel-based alloys. The results highlight the potential for optimizing recycling strategies and reducing material waste in additive manufacturing processes.zeige mehrzeige weniger

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Autor*innen:Rafael Kleba-EhrhardtORCiD, Josué DávilaORCiD, Johann GeisslerORCiD, Gunther MohrORCiD, Johannes Schmidt, Christoph HeinzeORCiD, Kai HilgenbergORCiD, Aleksander GurloORCiD, David KarlORCiD
Dokumenttyp:Zeitschriftenartikel
Veröffentlichungsform:Verlagsliteratur
Sprache:Englisch
Titel des übergeordneten Werkes (Englisch):Additive Manufacturing
Jahr der Erstveröffentlichung:2026
Organisationseinheit der BAM:9 Komponentensicherheit
9 Komponentensicherheit / 9.6 Additive Fertigung metallischer Komponenten
Veröffentlichende Institution:Bundesanstalt für Materialforschung und -prüfung (BAM)
Verlag:Elsevier B.V.
Jahrgang/Band:116
Aufsatznummer:105050
Erste Seite:1
Letzte Seite:16
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Freie Schlagwörter:Additive manufacturing; Powder bed fusion; Powder characterization; Powder oxidation; Powder recycling
Themenfelder/Aktivitätsfelder der BAM:Material
Material / Additive Fertigung
DOI:10.1016/j.addma.2025.105050
URN:urn:nbn:de:kobv:b43-654545
ISSN:2214-8604
Verfügbarkeit des Dokuments:Datei für die Öffentlichkeit verfügbar ("Open Access")
Lizenz (Deutsch):License LogoCreative Commons - CC BY - Namensnennung 4.0 International
Datum der Freischaltung:04.02.2026
Referierte Publikation:Ja
Datum der Eintragung als referierte Publikation:04.02.2026
Schriftenreihen ohne Nummerierung:Wissenschaftliche Artikel der BAM
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