Effect of powder recycling on room and elevated temperature damage tolerability of Inconel 718 alloy fabricated by laser powder bed fusion

Highlights: • Damage tolerability of L-PBF IN718 specimens made from virgin and recycled power was assessed at 25 and 650 °C. • Fatigue crack propagation behavior of L-PBF IN718 was not sensitive to powder recycling at 25 and 650 °C. • Fracture toughness of L-PBF IN718 tended to decrease marginally with powder recycling at 25 and 650 °C. Inconel 718 (IN718) specimens were prepared by laser powder bed fusion (L-PBF) process using either virgin or recycled powder to investigate the effect of powder recycling on the damage tolerability (i.e., fracture toughness (K_Q) and fatigue crack propagation (FCP)) at 25 and 650 °C. It was found that the K_Q value of L-PBF IN718 specimen decreased marginally, while the FCP behavior was unaffected, with powder recycling at 25 and 650 °C. Detailed fractographic and micrographic analyses were conducted to identify the reason for two different trends in static and dynamic damage tolerability of L-PBF IN718 specimen made from virgin and recycled powder.