From Waste To Feedstock: Feasibility Of Recycling AA5183 Alloy Chips Into Powders For Additive Manufacturing

Additive manufacturing (AM) represents an innovative production method that combines advanced technological capabilities with the potential for sustainable resource use, particularly in energy and powder materials. This study explores strategies to reduce the environmental impact of AM powders, focusing on vacuum inert gas atomization (VIGA) of a 5xxx series aluminum alloy powder. Industrial waste from metal forming processes was processed, inductively heated under vacuum, and melted. The resulting molten material was atomized using argon as an inert gas. Powder yields ranging from 70 to 75% of the input feedstock were achieved, with specific yield in the 20-63 µm range between 30 to 35%. The powders derived from waste feedstock displayed chemical and morphological properties comparable to those obtained through conventional ingot melting. These findings highlight the potential for reusing industrial waste in AM powder production, enhancing sustainability without compromising material performance.