Bhaduri, Debajyoti  ORCID: https://orcid.org/0000-0002-8270-388X, Baramate, Karan A., Gangopadhyay, Soumya, Singh, Sukhwinder, Lacan, Franck ORCID: https://orcid.org/0000-0002-3499-5240 and Ryan, Michael ORCID: https://orcid.org/0000-0002-8104-0121
2025.
A feasibility study on the circular manufacturing of sustainable metal additive manufacturing powders from machining chips.
International Journal of Advanced Manufacturing Technology
10.1007/s00170-025-15654-0
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Abstract
The holistic vision of the research is to develop a circular hybrid manufacturing framework to achieve ‘Net Zero’ for the additive manufacturing sector by producing sustainable powders from production scrap/machining chips. This paper reports initial feasibility study results from the foundation stage of the circular hybrid manufacturing framework that centers on generating additive manufacturing powders via solid-state crushing/ball milling of machining chips at room temperature. Here, the viability of the ball milling process to produce additive powders from three readily available chip materials is evaluated, viz. a low carbon steel (AISI 1020), and two aluminum alloy chips (AA6082-T6 and AA5083-H111). The ball-milled powders were characterized in terms of their morphology, size distribution, flowability, and phase analysis. The morphology/size distributions were found to be influenced by the chip materials and their length scale. Single-track laser melting of pre-placed AA6082 ball-milled powder particles was subsequently performed to emulate the laser powder bed fusion process. Cross-sectional micrographs demonstrated melting and bonding of the ball-milled particles to the AA6082 substrate. A further feasibility trial was undertaken to fabricate cubes from the ball-milled AA5083 powders via the powder bed fusion process. The microhardness (71–88 HV0.01) and microstructure of the specimens were comparable to rolled AA5083-H111 plates.
| Item Type: | Article |
|---|---|
| Date Type: | Published Online |
| Status: | In Press |
| Schools: | Schools > Engineering |
| Publisher: | Springer |
| ISSN: | 0268-3768 |
| Funders: | Welsh Government Ser Cymru; Net Zero Fund |
| Date of First Compliant Deposit: | 13 May 2025 |
| Date of Acceptance: | 27 April 2025 |
| Last Modified: | 03 Jun 2025 14:03 |
| URI: | https://orca.cardiff.ac.uk/id/eprint/178248 |
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