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The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing
Dube, T. M. 2025. The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing. Unpublished doctoral dissertation. Stellenbosch: Stellenbosch University [online]. Available: https://scholar.sun.ac.za...
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| Language: | English |
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Stellenbosch : Stellenbosch University
2025
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| _version_ | 1867613887468142592 |
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| access_status_str | Open Access |
| author | Dube, Tsepo Maqhetuka |
| author2 | Van der Merwe, Andre |
| author_browse | Dube, Tsepo Maqhetuka Van der Merwe, Andre |
| author_facet | Van der Merwe, Andre Dube, Tsepo Maqhetuka |
| author_sort | Dube, Tsepo Maqhetuka |
| collection | Thesis |
| dc_rights_str_mv | Stellenbosch University |
| description | Dube, T. M. 2025. The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing. Unpublished doctoral dissertation. Stellenbosch: Stellenbosch University [online]. Available: https://scholar.sun.ac.za/items/5759c187-a8c3-4f63-a8c0-99c5e4e61397 |
| format | Thesis |
| id | oai:scholar.sun.ac.za:10019.1/132169 |
| institution | Stellenbosch University (South Africa) |
| language | English |
| last_indexed | 2026-06-10T12:43:16.997Z |
| license_str | Other — see source repository |
| provenance_str_mv | Harvested via OAI-PMH from SUNScholar — Stellenbosch University Repository |
| publishDate | 2025 |
| publishDateRange | 2025 |
| publishDateSort | 2025 |
| publisher | Stellenbosch : Stellenbosch University |
| publisherStr | Stellenbosch : Stellenbosch University |
| record_format | dspace |
| source_str | SUNScholar — Stellenbosch University Repository |
| spelling | oai:scholar.sun.ac.za:10019.1/132169 The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing Dube, Tsepo Maqhetuka Van der Merwe, Andre Matope, Stephen Stellenbosch University. Faculty of Engineering. Dept. of Industrial Engineering. Titanium alloys Additive manufacturing Sustainable engineering UCTD Dube, T. M. 2025. The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing. Unpublished doctoral dissertation. Stellenbosch: Stellenbosch University [online]. Available: https://scholar.sun.ac.za/items/5759c187-a8c3-4f63-a8c0-99c5e4e61397 Thesis (PhD)--Stellenbosch University, 2025. ENGLISH ABSTRACT: This research is a techno-economic study based at Necsa (South African Nuclear Energy Cooperation). The research aimed to prove the feasibility of economically reconditioning Ti6Al4V powder for reuse; produce value chain documentation for economic spheroidisation and reconditioning as well as to simulate the spheroidisation process while focusing on particle behaviour. The Tekna 15 kW system machine was used for this research. The system can spheroidise and recondition titanium powder for selective laser melting. From the experiments that were conducted, it was found that the system can technically spheroidise different Ti6Al4V powder sizes. It was found that the system can produce 617 kg of titanium powder annually, at maximum capacity. The Tekna system was used as the template for the analysis and the framework can be used for different machine sizes. A value chain analysis was also conducted to evaluate all processes and the contribution they make to the quality of the final product. This value chain was used to determine the viability of each activity and to investigate some of the activities that could be improved to reduce cost and increase efficiency. The investigation shows that the 90-106 μm powder is economically and technically viable, with qualities similar to ASTM-F3001 values and low loss of Vanadium and Aluminium. Larger particle sizes exhibit negligible particle loss due to their low surface area-to-volume ratio. The profit margins are determined by the powder's selling price and input expenses. The 45-106 μm powder has lower selling prices but takes more helium to spheroidise, making it less profitable. The 90-106 μm powder is commercially and technically viable, with profit margins determined by the powder's selling price. As powder sizes increased, vaporisation decreased making the 90-106 μm powder the sole possible powder to spheroidise and meet AM criteria. Powders under 90 μm were found to be appropriate for spray coating but may not meet the standards of virgin powder due to the loss of elemental content. It was also proven that the inputs that can affect the profitability in spheroidisation are the purchase price of Ti6Al4V and the cost of helium. The research gave a guide on the influence of each input for anyone who would want to implement spheroidisation. A simulation was also developed using the Cradle Computational Fluid Dynamics software to simulate the conditions and the results of the spheroidisation system. A comparison was made between the simulation and the experimental results to check for any discrepancies and how they could be improved. This enabled the researcher to economically conduct research on spheroidisation strategies without incurring extra costs. The research highlighted the steps to commercialise the spheroidisation of Ti6Al4V. AFRIKAANSE OPSOMMING: Hierdie navorsing is 'n tegnologies-ekonomiese studie wat by Necsa (South African Nuclear Energy Cooperation) gebaseer is. Die navorsing het ten doel gehad om die haalbaarheid van die ekonomiese herverwerking van Ti6Al4V poeier vir hergebruik te bewys; waarde-ketting dokumentasie te produseer vir ekonomiese sferoidisering en herverwerking, sowel as om die sferoidiseringsproses te simuleer terwyl daar gefokus word op deeltjiegedrag. Die Tekna 15 kW stelselmachine is vir hierdie navorsing gebruik. Die stelsel kan titaniumpoeier sferoïdiseer en herverwerk vir selektiewe laser smelting. Uit die eksperimente wat uitgevoer is, is daar gevind dat die stelsel tegnies verskillende Ti6Al4V poeiergroottes kan sferoïdiseer. Daar is gevind dat die stelsel 617 kg titaniumpoeier jaarliks kan produseer, by maksimum kapasiteit. Die Tekna-stelsel is as die sjabloon vir die analise gebruik, en die raamwerk kan vir verskillende masgrootte gebruik word. 'n Waardekettinganalise is ook uitgevoer om al die prosesse te evalueer en die bydrae wat hulle lewer tot die kwaliteit van die finale produk. Hierdie waardeketting is gebruik om die lewensvatbaarheid van elke aktiwiteit te bepaal en om sommige van die aktiwiteite te ondersoek wat verbeter kan word om koste te verlaag en doeltreffendheid te verhoog. Die ondersoek toon dat die 90-106 μm poeier ekonomies en tegnies haalbaar is, met eienskappe wat soortgelyk is aan ASTM-F3001 waardes en 'n lae verlies van Vanadium en Aluminium. Groter deeltjiesgrootte toon verwaarloosbare deeltjieverlies weens hul lae oppervlak-tot-volume verhouding. Die winsmarges word bepaal deur die poeier se verkoopprys en insetkoste. Die 45-106 μm poeier het laer verkooppryse, maar dit neem meer helium om te sferoidiseer, wat dit minder winsgewend maak. Die 90-106 μm poeier is kommersieel en tegnies lewensvatbaar, met winsmarges wat bepaal word deur die poeier se verkoopprys. Namate die poeiergrootte toegeneem het, het verdamping afgeneem, wat die 90-106 μm poeier die enigste moontlike poeier gemaak het om te sferoidiseer en aan AM-kriteria te voldoen. Poeders onder 90 μm is gevind om geskik te wees vir spuitbedekking, maar mag nie aan die standaarde van ongerepte poeier voldoen nie weens die verlies van elementêre inhoud. Daar is ook bewys gelewer dat die insette wat die winsgewendheid in sferoidisering kan beïnvloed, die aankoopprys van Ti6Al4V en die koste van helium is. Die navorsing het 'n gids verskaf oor die invloed van elke inset vir enigiemand wat spheroidisering wil implementeer. 'n Simulasie is ook ontwikkel met behulp van die Cradle Computational Fluid Dynamics-sagteware om die toestande en die resultate van die sferoidiseringstelsel te simuleer. 'n Vergelyking is gemaak tussen die simulasie en die eksperimentele resultate om enige verskille na te gaan en hoe dit verbeter kan word. Dit het die navorser in staat gestel om ekonomies navorsing oor sferoidiseringstrategieë te doen sonder om ekstra koste te incurr. Die navorsing het die stappe beklemtoon om die sferoidisering van Ti6Al4V kommersieel te maak. Doctoral 2025-05-28T11:46:47Z 2025-05-28T11:46:47Z 2025-03 Thesis https://scholar.sun.ac.za/handle/10019.1/132169 en Stellenbosch University xvii, 202 pages : illustrations application/pdf Stellenbosch : Stellenbosch University |
| spellingShingle | Titanium alloys Additive manufacturing Sustainable engineering UCTD Dube, Tsepo Maqhetuka The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing |
| title | The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing |
| title_full | The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing |
| title_fullStr | The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing |
| title_full_unstemmed | The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing |
| title_short | The techno-economic aspects for the qualification of sustainable reconditioning and spheroidisation of Titanium Alloy (Ti6Al4V) powder for additive manufacturing |
| title_sort | techno economic aspects for the qualification of sustainable reconditioning and spheroidisation of titanium alloy ti6al4v powder for additive manufacturing |
| topic | Titanium alloys Additive manufacturing Sustainable engineering UCTD |
| url | https://scholar.sun.ac.za/handle/10019.1/132169 |
| work_keys_str_mv | AT dubetsepomaqhetuka thetechnoeconomicaspectsforthequalificationofsustainablereconditioningandspheroidisationoftitaniumalloyti6al4vpowderforadditivemanufacturing AT dubetsepomaqhetuka technoeconomicaspectsforthequalificationofsustainablereconditioningandspheroidisationoftitaniumalloyti6al4vpowderforadditivemanufacturing |