Parametric modeling of cradle-to-gate carbon emissions from gas-atomized AISI 316L powders under closed-loop feedstock strategies

This study introduces a parametric framework for the cradle-to-gate assessment of carbon emissions associated with the production of gas-atomized AISI 316L stainless steel powders intended for use in additive manufacturing and other powder metallurgy processes. The model provides a detailed representation of upstream material flows and includes all major unit operations involved in powder production, such as feedstock preparation, gas atomization, sieving and blending, and packing. By varying the composition of the feedstock charged into the atomizer crucible, the framework enables the estimation of carbon emissions across a wide range of scenarios reflecting alternative sourcing strategies. The case study on AISI 316L highlights the environmental benefits of integrating closed-loop material flows, including the recirculation of off-specification powders and the direct use of compatible metallic scrap. Furthermore, broadening the acceptable powder size range significantly improves atomization yield, thereby reducing the specific carbon intensity of usable powder output. Such an approach lays the foundation for the development of robust decision-support tools for process planning in gas atomization, with direct implications for industrial-scale powder production.