Background
In laser powder bed fusion (LPBF) additive manufacturing, 20–30% of metal powder feedstock becomes unusable after multiple cycles of sieving and reclaiming. This is due to deviations in particle size and geometry, which can lead to build defects and failures. These out-of-spec powders are typically stored, creating logistical, cost, and safety challenges, as no practical method exists to recycle them back into the manufacturing loop. There is a growing need particularly within Department of Defense (DoD) applications for innovative, economically viable, and environmentally friendly recycling processes that can reintegrate these powders into the production cycle, thereby strengthening the domestic additive manufacturing feedstock supply chain.
Invention Description
Researchers at Arizona State University have developed a new thermoacoustic consolidation method to process out-of-spec LPBF metal powder, and produce continuous & discrete feedstocks for direct use in other metal AM processes such as DED or WAAM, or other manufacturing processes such as MIG and TIG welding. The core concept of this solid-state process is that applying both low heat and ultrasonic vibration energy, the consolidation and solid-state fusion bonding of powder particles can occur rapidly and reach high densities in the consolidated product. This low temperature, rapid process can be integrated into a continuous production tool where both the ultrasonic and thermal energy are applied to the powder in a roll-forming environment.
Potential Applications:
Benefits and Advantages: