Effect of recycled powder content on the structure and mechanical properties of Ti-6Al-4V alloy produced by direct energy deposition.

• Ti-6Al-4V DED samples with different content of recycled powder demonstrated the stable chemical composition. • The tendency of decrease the α lath size with increase of recycled powder content in Ti-6Al-4V samples was determined. • The degradation of mechanical properties of annealed DED samples with increase of recycled powder content was not observed. • No difference in fracture surfaces with different contents of the used powder. [Display omitted] Direct energy deposition (DED) is a promising additive manufacturing technique in the area of aerospace, automotive, shipbuilding and medical industries. DED allows producing large-scale parts that imply the use of a significant amount of powders. Powder reuse is an important task that leads to a reduction in the cost of the final products. In this work, Ti-6Al-4V samples were fabricated by DED technique with a mixture of unused and recycled powders in the recycled powder content of 0%, 10%, 25%, and 50%. The results show that the morphology of the powder does not change significantly due to a low number of powder uses. Chemical analysis reveals a slight decrease of V in the recycled powder. The evolution of macrostructure with increasing recycled powder content was not revealed. In the as-built samples, the columnar prior β grains grow toward the build direction with a typical Widmanstätten structure consisting of the thin α' laths. The mix of Widmanstätten microstructure and basket weave microstructure appears after the annealing at 800 ℃. Furthermore, the horizontal and vertical annealed samples exhibit ductile fracture and inconspicuous anisotropy of tensile and impact mechanical properties. [ABSTRACT FROM AUTHOR]