Ti-6Al-4V powder reuse in laser powder bed fusion (L-PBF): The effect on porosity, microstructure, and mechanical behavior

•Powder reuse effects on mechanical properties of L-PBF Ti64 were investigated.•Location effects; i.e., upstream and downstream of shield gas flow, were studied.•More and larger defects were formed in downstream locations due to spattering.•Powder reuse slightly increased strength and reduced ductility due to O pickup.•Fatigue resistance in the upstream locations improved with limited powder reuse.