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Feasibility Study on Reusing Recycled Premixed Multi-Material Powder in the Laser Powder Bed Fusion Process for

Shiming Gao^1,2, Shuo Qu³, Junhao Ding³

¹Zhejiang Engineering Research Center of Advanced Water Conservancy Equipment, Zhejiang University of Water Resources and Electric Power, Hangzhou 310018, China.

|October 29, 2025

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This summary is machine-generated.

This study demonstrates reusing mixed metal powders in thermal management applications. Effective structural design compensates for material property loss, enabling waste powder recycling for heat exchangers.

Area of Science:

Materials Science
Manufacturing Engineering
Thermal Engineering

Background:

Multi-material manufacturing generates waste premixed powders.
Reusing these powders is challenging due to potential performance degradation.
Thermal management applications offer potential for utilizing recycled materials.

Purpose of the Study:

To investigate the feasibility of reusing premixed waste powders in non-critical thermal management applications.
To develop an effective structure design strategy to compensate for performance loss in reused materials.
To demonstrate the application of recycled Cu-Ni powder in heat exchanger production.

Main Methods:

Powder characterization (morphology, homogeneity, flowability).
Mechanical testing (compression, tensile) of fabricated Cu-Ni specimens.

Keywords:

Cu-Ni heat exchanger laser powder bed fusion reused powder

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Numerical analysis of heat transfer mechanisms (conduction vs. convection).

Experimental validation of heat exchanger performance.

Main Results:

Cu-Ni powder mixture showed good homogeneity and acceptable flowability.
Fabricated Cu-Ni specimens exhibited favorable energy absorption and ductility.
Convection significantly dominated heat transfer compared to conduction.
Cu-Ni heat exchangers achieved performance comparable to pure Cu ( < 1.3% deviation).

Conclusions:

Effective structure design can mitigate performance loss in reused materials.
Premixed waste powders can be successfully recycled for heat exchanger manufacturing.
This approach offers a viable solution for waste reduction in additive manufacturing.