A thin-walled product made of AZ31 magnesium alloy was successfully fabricated using wire-feed electron-beam additive manufacturing. The microstructure of the initial wire, used as a precursor, comprises a α-Mg(Al, Zn) solid solution and a minor amount of the Al₈Mn₅ intermetallic phase. The microstructure of the as-printed AZ31 alloy exhibits a three-phase structure: α-Mg(Al, Zn), Al₈Mn₅, and β-Mg₁₇Al₁₂. It was proposed that the secondary β-phase was formed via a primary solidification process upon the cooling of the welded layers. The texture effect was evident in the direction, corresponding to the printing direction, while other crystallographic orientations demonstrated near-equal pole densities as the XRD lines. The yield strength for the as-printed alloy was found to be 86 MPa; the tensile strength reached 240 MPa; and the relative elongation was 21.5%. For the first time, the corrosion resistance of an EBAM-fabricated AZ31 alloy was studied. It was revealed that the corrosion current density in the referenced as-cast and as-printed alloys was below 2·10⁻⁴ A/cm².

Sustainable feedstock management remains a major challenge in laser beam powder bed fusion (PBF-LB), where conventional reuse strategies are typically limited to sieving and blending rather than full material regeneration. Ultrasonic atomization (UA) offers a fundamentally different powder production route based on capillary-wave instabilities induced at the surface of a molten metal by high-frequency vibrations. In contrast to turbulence-driven atomization, droplet formation in UA is primarily governed by ultrasonic frequency and intrinsic thermophysical properties of the melt, enabling quasi-deterministic particle formation with high sphericity and reduced satellite formation. In this study, ultrasonic atomization was investigated as a closed-loop route for converting PBF-LB-manufactured 316L stainless steel parts into reusable powder. Printed rods were remelted and atomized under controlled variation of electric current and vibration amplitude. The resulting powders were characterized in terms of morphology, internal microstructure, particle size distribution, chemical composition, and gas impurity content. UA produced highly spherical particles with reduced internal porosity and improved flowability compared to the initial gas-atomized powder, while preserving the principal alloying elements. An increase in oxygen content was observed after recycling, attributed to selective high-temperature oxidation under residual oxygen in nominally inert conditions. The results establish a mechanistic framework for transforming consolidated PBF-LB material into secondary feedstock and identify key parameters governing structural and compositional stability in closed-loop recycling.