Atomized scrap powder feedstock for sustainable Inconel 718 additive manufacturing via LPBF: a study of static and fatigue properties

Inconel 718 is a popular superalloy with high strength and corrosion-resistance properties that make it widely used in aerospace and nuclear industries. The conventional production of Inconel 718 powder feedstock involves a considerable amount of energy consumption and greenhouse gas emissions. This study investigates the feasibility of using atomized metallic scrap to produce Inconel 718 powder feedstock, as a more sustainable alternative. Life cycle assessments showed that this approach reduces carbon footprint and energy consumption by more than 90% compared to conventional production methods. The study also carried out comparative microstructural, static and fatigue analyses to address concerns about potential impurities in the secondary-source powder feedstock. The results indicate that this secondary-source powder feedstock can achieve properties comparable to those of conventionally processed powders, with negligible loss in ductility and fatigue strength, without requiring ad-hoc tuning of the LPBF process parameters. Overall, the findings suggest that using Inconel 718 powder feedstock produced from secondary sources can be a promising and sustainable alternative to conventional production methods.