nach oben

Erschienen in:

2018 | OriginalPaper | Buchkapitel

Surface Finish Improvement of Additive Manufactured Metal Parts

verfasst von : Hany Hassanin, Amr Elshaer, Redha Benhadj-Djilali, Francesco Modica, Irene Fassi

Erschienen in: Micro and Precision Manufacturing

Verlag: Springer International Publishing

Einloggen

Aktivieren Sie unsere intelligente Suche, um passende Fachinhalte oder Patente zu finden.

search-config

KI-gestützte Suche

Aus

Abstract

Unlike materials subtractive technologies, additive manufacturing (AM) works on producing near-net-shape components according to a specific design at which the synthesis is achieved layer by layer. Additive manufacturing allows design freedom, making design-driven manufacturing a reality. However, its poor surface quality is considered as one of the key challenges that are worth to overcome. The main objective of this chapter is to report a comprehensive overview of the techniques used to improve the surface finish and their advancements of products made by metal additive manufacturing (AM) technologies and to highlight experimental processes and data. Powder bed fusion (PBF) and direct laser deposition (DLD) are the main processes covered in this review. The chapter starts with the literature review and introduction to the main metal AM processes and their surface roughness limitations, the effect of their parameters and the effect of the laser re-melting on the surface quality. Next, it is followed by a number of surface finishing techniques such as laser polishing, chemical and electropolishing. Experimental results of post-surface finishing of AM parts by microelectrical discharge machining are also presented.

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Vorheriges Kapitel Condition Monitoring in Micro-Injection Moulding

Nächstes Kapitel Precision Coatings

Bhattacharjee N, Urrios A, Kang S, Folch A (2016) The upcoming 3D-printing revolution in microfluidics. Lab Chip Miniaturisation Chem Biol 16:1720–1742CrossRef

Daly A (2016) Socio-legal aspects of the 3D printing revolution

Wirth M, Thiesse F (2014) Shapeways and the 3D printing revolution. In: ECIS 2014 Proceedings—22nd European Conference on Information Systems

UK Government Office for Science and Department for Business Innovationand Skills, The future of manufacturing: a new era of opportunity and challenge for the UK., 2013

Cox SC, Jamshidi P, Eisenstein NM, Webber MA, Hassanin H, Attallah MM et al (2016) Adding functionality with additive manufacturing: fabrication of titanium-based antibiotic eluting implants. Mater Sci Eng, C 64:407–415CrossRef

Li S, Hassanin H, Attallah MM, Adkins NJE, Essa K (2016) The development of TiNi-based negative Poisson’s ratio structure using selective laser melting. Acta Mater 105:75–83CrossRef

Qiu C, Adkins NJE, Hassanin H, Attallah MM, Essa K (2015) In-situ shelling via selective laser melting: modelling and microstructural characterisation. Mater Des 87:845–853CrossRef

Qiu C, Yue S, Adkins NJE, Ward M, Hassanin H, Lee PD et al (2015) Influence of processing conditions on strut structure and compressive properties of cellular lattice structures fabricated by selective laser melting. Mater Sci Eng, A 628:188–197CrossRef

Yeh CC (2014) Trend analysis for the market and application development of 3D printing. Int J Autom Smart Technol 4:1–3CrossRef

10.

Seifi M, Salem A, Beuth J, Harrysson O, Lewandowski JJ (2016) Overview of materials qualification needs for metal additive manufacturing. JOM 68:747–764CrossRef

11.

Frazier WE (2014) Metal additive manufacturing: a review. J Mater Eng Perform 23:1917–1928CrossRef

12.

Murr LE, Gaytan SM, Ramirez DA, Martinez E, Hernandez J, Amato KN et al (2012) Metal fabrication by additive manufacturing using laser and electron beam melting technologies. J Mater Sci Technol 28:1–14CrossRef

13.

Yap CY, Chua CK, Dong ZL, Liu ZH, Zhang DQ, Loh LE et al (2015) Review of selective laser melting: Materials and applications. Appl Phys Rev 2

14.

Körner C (2016) Additive manufacturing of metallic components by selective electron beam melting—a review. Int Mater Rev 61:361–377CrossRef

15.

Shamsaei N, Yadollahi A, Bian L, Thompson SM (2015) An overview of direct laser deposition for additive manufacturing; Part II: mechanical behavior, process parameter optimization and control. Add Manuf 8:12–35

16.

Jones J, Whittaker M, Buckingham R, Johnston R, Bache M, Clark D (2017) Microstructural characterisation of a nickel alloy processed via blown powder direct laser deposition (DLD). Mater Des 117:47–57CrossRef

17.

Isanaka SP, Karnati S, Liou F (2016) Blown powder deposition of 4047 aluminum on 2024 aluminum substrates. Manuf Lett 7:11–14CrossRef

18.

Ding D, Pan Z, Cuiuri D, Li H (2015) Wire-feed additive manufacturing of metal components: technologies, developments and future interests. Int J Adv Manuf Technol 81:465–481CrossRef

19.

Lancea C, Chicos LA, Zaharia SM, Pop MA (2017) Microstructure and micro-hardness analyses of titanium alloy Ti-6Al-4V parts manufactured by selective laser melting. In: MATEC Web of Conferences

20.

Agapovichev AV, Kokareva VV, Smelov VG, Sotov AV (2016) Selective laser melting of titanium alloy: investigation of mechanical properties and microstructure. In: IOP Conference Series: Materials Science and Engineering

21.

Bassani P, Biffi CA, Casati R, Alarcon AZ, Tuissi A, Vedani M (2016) Properties of aluminium alloys produced by selective laser melting. In: Key Engineering Materials, vol 710, pp 83–88

22.

Olakanmi EO, Cochrane RF, Dalgarno KW (2015) A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing, microstructure, and properties. Prog Mater Sci 74:401–477CrossRef

23.

Lykov PA, Baitimerov RM, Vaulin SD (2016) Influence of SLM process parameters on porosity of nickel base heat resistance alloy EP648. In: Materials Science Forum, vol 843, pp 253–258

24.

Carter LN, Martin C, Withers PJ, Attallah MM (2014) The influence of the laser scan strategy on grain structure and cracking behaviour in SLM powder-bed fabricated nickel superalloy. J Alloy Compd 615:338–347CrossRef

25.

Sander J, Hufenbach J, Bleckmann M, Giebeler L, Wendrock H, Oswald S et al (2017) Selective laser melting of ultra-high-strength TRIP steel: processing, microstructure, and properties. J Mater Sci 52:4944–4956CrossRef

26.

Yusuf SM, Chen Y, Boardman R, Yang S, Gao N (2017) Investigation on porosity and microhardness of 316L stainless steel fabricated by selective laser melting. Metals 7

27.

Song B, Dong SJ, Liao HL, Coddet C (2012) Morphology evolution mechanism of single tracks of FeAl intermetallics in selective laser melting. Mater Res Innovations 16:321–325CrossRef

28.

Kotoban DV, Nazarov AP, Shishkovsky IV (2015) Comparative study of selective laser melting and direct laser metal deposition of Ni<inf>3</inf>Al intermetallic alloy. In: Materials Science Forum, vol 834, pp 103–111

29.

Gu D, Dai D, Chen W, Chen H (2016) Selective laser melting additive manufacturing of hard-to-process tungsten-based alloy parts with novel crystalline growth morphology and enhanced performance. J Manuf Sci Eng Trans ASME 138

30.

Delgado J, Ciurana J, Rodríguez CA (2012) Influence of process parameters on part quality and mechanical properties for DMLS and SLM with iron-based materials. Int J Adv Manuf Technol 60:601–610CrossRef

31.

Hrabe N, Gnäupel-Herold T, Quinn T (2017) Fatigue properties of a titanium alloy (Ti–6Al–4V) fabricated via electron beam melting (EBM): effects of internal defects and residual stress. Int J Fatigue 94:202–210CrossRef

32.

Algardh JK, Horn T, West H, Aman R, Snis A, Engqvist H et al (2016) Thickness dependency of mechanical properties for thin-walled titanium parts manufactured by Electron Beam Melting (EBM)^®. Additive Manufacturing 12:45–50CrossRef

33.

Ramsperger M, Singer RF, Körner C (2016) Microstructure of the nickel-base superalloy CMSX-4 fabricated by selective electron beam melting. Metall Mater Trans A 47:1469–1480CrossRef

34.

Zhong Y, Rännar LE, Liu L, Koptyug A, Wikman S, Olsen J et al (2017) Additive manufacturing of 316L stainless steel by electron beam melting for nuclear fusion applications. J Nucl Mater 486:234–245CrossRef

35.

Mazumder J, Dutta D, Kikuchi N, Ghosh A (2000) Closed loop direct metal deposition: art to part. Opt Lasers Eng 34:397–414

36.

Miller S, Heath M, Woods B, Costello A, Dolan D, Sears J (2005) Fabrication of titanium automotive parts with Laser Powder Deposition. In: MPMD sixth global innovations proceedings—trends in materials and manufacturing technologies for transportation industries and powder metall. Research and development in the transportation industry, pp 293–301

37.

Riza SH, Masood SH, Wen C, Ruan D, Xu S (2014) Dynamic behaviour of high strength steel parts developed through laser assisted direct metal deposition. Mater Des 64:650–659CrossRef

38.

Yan A, Yang T, Wang Y, Ma Z, Du Y, Wang Z (2016) Effect of tungsten powder particle size and shape on consolidation and microstructure of W-xCu composites by selective laser melting. Zhongguo Jiguang/Chin J Lasers 43

39.

Wendt U, Settegast S, Grodrian IU (2003) Laser alloying of aluminum with titanium wire. J Mater Sci Lett 22:1319–1322CrossRef

40.

Zhang YN, Cao X, Wanjara P (2015) Fiber laser deposition of nickel-based superalloys using filler wire feed. In: Proceedings of the ASME turbo expo

41.

Nie Z, Wang G, McGuffin-Cawley JD, Narayanan B, Zhang S, Schwam D et al (2016) Experimental study and modeling of H13 steel deposition using laser hot-wire additive manufacturing. J Mater Process Technol 235:171–186CrossRef

42.

Ghanekar A, Crawford R (2003) Optimization of SLS process parameters using D-optimality. 4th international solid freeform fabrication symposium. Austin, Texas, USA, p 348

43.

Calignano F, Manfredi D, Ambrosio EP, Iuliano L, Fino P (2013) Influence of process parameters on surface roughness of aluminum parts produced by DMLS. Int J Adv Manuf Technol 67:2743–2751CrossRef

44.

Bacchewar PB, Singhal SK, Pandey PM (2007) Statistical modelling and optimization of surface roughness in the selective laser sintering process. Proc Inst Mech Eng, Part B: J Eng Manuf 221:35–52CrossRef

45.

Kaddar W (2010) “Die generative Fertigung mittels Laser Sintern,” Ph.D., Abteilung Maschinenbau und Verfahrenstechnik Universität Duisburg-Essen

46.

Ek RK, Rännar L-E, Bäckstöm M, Carlsson P (2016) The effect of EBM process parameters upon surface roughness. Rapid Prototyping J 22:495–503CrossRef

47.

Safdar A, He HZ, Wei LY, Snis A, de Paz LEC (2012) Effect of process parameters settings and thickness on surface roughness of EBM produced Ti‐6Al‐4V. Rapid Prototyping J 18:401–408

48.

Kleszczynski S, Ladewig A, Friedberger K, zur Jacobsmühlen J, Merhof D, Witt G (2015) Position dependency of surface roughness in parts from laser beam melting systems. In: 26th International Solid Free Form Fabrication (SFF) Symposium, USA, pp 360–370

49.

Mahdi J, Radovan K (2015) The influence of heat accumulation on the surface roughness in powder-bed additive manufacturing. Surf Topogr: Metrol Prop 3:014003CrossRef

50.

Vinod AR, Srinivasa CK, Keshavamurthy R, Shashikumar PV (2016) A novel technique for reducing lead-time and energy consumption in fabrication of Inconel-625 parts by laser-based metal deposition process. Rapid Prototyping J 22:269–280CrossRef

51.

Gharbi M, Peyre P, Gorny C, Carin M, Morville S, Le Masson P et al (2013) Influence of various process conditions on surface finishes induced by the direct metal deposition laser technique on a Ti–6Al–4V alloy. J Mater Process Technol 213:791–800

52.

Nowotny S, Thieme S, Albert D, Kubisch F, Kager R, Leyens C (2013) Generative manufacturing and repair of metal parts through direct laser deposition using wire material. In: Kovács GL, Kochan D (eds) Digital product and process development systems: IFIP TC 5 international conference, NEW PROLAMAT 2013, Dresden, Germany, 10–11 Oct 2013. Springer, Berlin, pp 185–189

53.

Alrbaey K, Wimpenny D, Tosi R, Manning W, Moroz A (2014) On optimization of surface roughness of selective laser melted stainless steel parts: a statistical study. J Mater Eng Perform 23:2139–2148CrossRef

54.

Smith BH, See T, Hiersemenzel F, Kaja K, Antar M (2016) Laser polishing of additive manufactured steel and titanium components. In: Proceedings—ASPE/euspen 2016 summer topical meeting: dimensional accuracy and surface finish in additive manufacturing, pp 22–27

55.

Ross I, Kumstel J, Bremen S, Willenborg E (2015) Laser polishing of laser additive manufactured surfaces made from Inconel 718 and ASTM F75. In: Proceedings—ASPE 2015 spring topical meeting: achieving precision tolerances in additive manufacturing, pp 136–140

56.

Ma CP, Guan YC, Zhou W (2017) Laser polishing of additive manufactured Ti alloys. Opt Lasers Eng 93:171–177

57.

Schanz J, Hofele M, Hitzler L, Merkel M, Riegel H (2016) Laser polishing of additive manufactured AlSi10Mg parts with an oscillating laser beam. In: Advanced Structured Materials, vol 61, pp 159–169

58.

Rosa B, Mognol P, Hascoët J-Y (2015) Laser polishing of additive laser manufacturing surfaces. J Laser Appl 27:S29102CrossRef

59.

Dadbakhsh S, Hao L, Kong CY (2010) Surface finish improvement of LMD samples using laser polishing. Virtual Phys Prototyping 5:215–221CrossRef

60.

Marimuthu S, Triantaphyllou A, Antar M, Wimpenny D, Morton H, Beard M (2015) Laser polishing of selective laser melted components. Int J Mach Tools Manuf 95:97–104CrossRef

61.

Burzic B, Hofele M, Mürdter S, Riegel H (2017) Laser polishing of ground aluminum surfaces with high continuous wave laser. J Laser Appl 29

62.

Bhaduri D, Penchev P, Batal A, Dimov S, Soo SL, Sten S et al (2017) Laser polishing of 3D printed mesoscale components. Appl Surf Sci 405:29–46CrossRef

63.

Chang CS, Chen TH, Li TC, Lin SL, Liu SH, Lin JF (2016) Influence of laser beam fluence on surface quality, microstructure, mechanical properties, and tribological results for laser polishing of SKD61 tool steel. J Mater Process Technol 229:22–35CrossRef

64.

Bordatchev EV, Hafiz AMK, Tutunea-Fatan OR (2014) Performance of laser polishing in finishing of metallic surfaces. Int J Adv Manuf Technol 73:35–52CrossRef

65.

Łyczkowska E, Szymczyk P, Dybała B, Chlebus E (2014) Chemical polishing of scaffolds made of Ti–6Al–7Nb alloy by additive manufacturing. Arch Civil Mech Eng 14:586–594

66.

Pyka G, Burakowski A, Kerckhofs G, Moesen M, Van Bael S, Schrooten J et al (2012) Surface modification of Ti6Al4V open porous structures produced by additive manufacturing. Adv Eng Mater 14:363–370CrossRef

67.

Alrbaey K, Wimpenny DI, Al-Barzinjy AA, Moroz A (2016) Electropolishing of Re-melted SLM Stainless Steel 316L Parts Using Deep Eutectic Solvents: 3 × 3 Full Factorial Design. J Mater Eng Perform 25:2836–2846CrossRef

68.

Modica F, Marrocco V, Fassi I (2012) Machining of ceramic Si3N4-TiN scaffolds using micro-EDM. In: proceeding of 1st International Conference on Design and PROcesses for MEdical Device, pp 139–142

69.

Tiwary AP, Pradhan BB, Bhattacharyya B (2015) Study on the influence of micro-EDM process parameters during machining of Ti–6Al–4V superalloy. Int J Adv Manuf Technol 76:151–160

70.

Maradia U, Scuderi M, Knaak R, Boccadoro M, Beltrami I, Stirnimann J et al (2013) Super-finished Surfaces using Meso-micro EDM. Procedia CIRP 6:157–162

71.

Yu ZY, Masuzawa T, Fujino M (1998) Micro-EDM for three-dimensional cavities—development of uniform wear method. CIRP Ann Manuf Technol 47:169–172

72.

Modica F, Basile V, Marrocco V, Fassi I (2016) A new process combining micro-electro-discharge-machining milling and sinking for fast fabrication of microchannels with draft angle. J Micro Nano-Manuf 4:024501

Titel: Surface Finish Improvement of Additive Manufactured Metal Parts
verfasst von: Hany Hassanin
Amr Elshaer
Redha Benhadj-Djilali
Francesco Modica
Irene Fassi
Verlag: Springer International Publishing
Buch: Micro and Precision Manufacturing
Print ISBN: 978-3-319-68800-8

Electronic ISBN: 978-3-319-68801-5

Copyright-Jahr: 2018
DOI: https://doi.org/10.1007/978-3-319-68801-5_7

Premium Partner

Marktübersichten

Die im Laufe eines Jahres in der „adhäsion“ veröffentlichten Marktübersichten helfen Anwendern verschiedenster Branchen, sich einen gezielten Überblick über Lieferantenangebote zu verschaffen.

Zur Marktübersicht