A sustainable strategy to improve the wear resistance of direct metal Laster sintering based AlSi10Mg parts through the use of leftover powder

Purpose This study aims to examine the influence of key direct metal Laster sintering (DMLS) parameters on powder reutilization to maintain powder quality, enhance mechanical performance and improve wear resistance. Given the high cost of metal powders and their strong impact on final part characteristics, optimizing powder reuse is essential for sustainable and efficient manufacturing. Design/methodology/approach Laser interaction time (LIT) values of 100, 125 and 150 µs and track spacing (TS) of 0.09, 0.15 and 0.21 mm were investigated to determine their effects on powder reusability and part properties. Machine learning models – CatBoost and support vector machine (R² = 1.000) – were used to accurately predict density, hardness and wear resistance, enabling precise optimization of process parameters. Two representative parameter combinations were comparatively analyzed to evaluate individual contributions to wear performance. Findings The optimal combination of LIT = 150 µs and TS = 0.09 mm with four powder reuse cycles yielded a maximum relative density of 99.23%, a minimal wear rate of 2.24 × 10?4 mm³/Nm and a reduced indentation depth of 744.2 nm. Wear mechanism analysis revealed the formation of cladded particles due to multiple reuse cycles of AlSi10Mg powder, which acted as a protective barrier and enhanced wear resistance. Originality/value This work provides a data-driven framework for optimizing DMLS powder reuse through integrated experimental and machine learning approaches. The findings support improved material efficiency and demonstrate the suitability of reused AlSi10Mg powder for high-performance applications such as gearbox casings and internal automotive components.