Application of mechanical surface finishing processes for roughness reduction and fatigue improvement of additively manufactured Ti-6Al-4V parts
TL;DR: In this paper, four different mechanical surface finishing processes were applied separately on plates and fatigue coupons in order to reduce the surface roughness: milling, blasting, vibratory grinding and a micro machining process.
About: This article is published in International Journal of Fatigue.The article was published on 2017-09-01. It has received 226 citations till now. The article focuses on the topics: Surface roughness & Surface finish.
Citations
More filters
TL;DR: In this paper, the authors review the literature on the influential microstructural attributes on fatigue performance of additive manufacturing (AM) parts with a focus on generated defects, including defect-based, microstructure-sensitive, and multiscale models.
309 citations
TL;DR: In this paper, an eXtended defect zone (XDZ) describing the propensity for local plasticity during fatigue around a defect has been shown through numerical analysis to be a good indicator of the ranking of the threat to fatigue caused by differently located manufacturing defects.
192 citations
TL;DR: In this article, various treatments applied to as-built samples fabricated using different additive manufacturing technologies are introduced and discussed, and the results obtained from different categories of post-treatments are compared and reviewed.
Abstract: Metal additive manufacturing is a rapidly expanding area owing to its capacity to fabricate parts of intricate geometries with customized features for a wide range of applications. However, these parts generally exhibit inadequate and poor surface quality in the as-built configuration. The surface imperfections and defects ranging from staircase effect due to the layer by layer nature of the deposition techniques, partially fused feedstock material, balling effects, spatters, or inadequate fusion lead to a notably irregular surface morphology. This high surface roughness can significantly deteriorate the performance of the additive manufactured parts imposing a substantial limit on their prospective applications; for instance, fatigue performance, wear and scratch resistance, dimensional accuracy, and aesthetical aspects can be highly affected by these surface defects. A great effort has been lately dedicated to developing post-treatments for improving the surface quality of additively manufactured metallic parts. In this paper, various treatments applied to as-built samples fabricated using different additive manufacturing technologies are introduced and discussed. The advances in this area are highlighted, and the results obtained from different categories of post-treatments are compared and reviewed. Challenges and opportunities to gain more control on the surface roughness of additively manufactured metallic parts through the application of these post-treatments are addressed.
176 citations
TL;DR: In this article, the authors identify the current barriers to the progression of additive manufacturing for end-use products from an industrial perspective and understand the nature of those barriers, including education, cost, design, software, materials, traceability, machine constraints, in-process monitoring, mechanical properties, repeatability, scalability, validation, standards, quality, inspection, tolerances, finishing and sterilisation.
152 citations
Cites background from "Application of mechanical surface f..."
...Options for surface finishing of AM parts described in research literature include mechanical blasting, chemical etching, electro polishing, laser ablation, micro-machining and vibratory grinding (Bagehorn et al., 2017; Lhuissier et al., 2016; Longhitano et al., 2015; Mohammad et al., 2016; Wang et al., 2016)....
[...]
...…surface finishing of AM parts described in research literature include mechanical blasting, chemical etching, electro polishing, laser ablation, micro-machining and vibratory grinding (Bagehorn et al., 2017; Lhuissier et al., 2016; Longhitano et al., 2015; Mohammad et al., 2016; Wang et al., 2016)....
[...]
01 Apr 2018-Precision Engineering-journal of The International Societies for Precision Engineering and Nanotechnology
TL;DR: In this paper, the effect of heat treatment on each scale of the topography is also discussed, and the authors make a critical review of measuring techniques at different scales to enlighten the different surface generation phenomena occurring during additive manufacturing.
Abstract: Topographies are one of the challenges for the development of the metal additive manufacturing promising technique. The article investigates multi scale topographies (from form to roughness) of as built surfaces generated by selective laser melting (SLM). Different building inclinations of samples were observed both for upskin and downskin surfaces with a wide range of measuring techniques. The two main aims are: (i) to make a critical review of measuring techniques at different scales, (ii) to enlighten the different surface generation phenomena (and the corresponding scale) occurring during additive manufacturing. The effect of heat treatment on each scale of the topography is also discussed. It is found that the focus variation technique is well suited for AM surfaces. Concerning the observation of the inclined surfaces, some parameters are emphasized as good indicators of typical signatures of AM surfaces: isotropy for the weld track component, the skewness and Rsm for the staircase effect, fractal dimension for the presence of partly melted particles. The different parameters studied helps to model and understand the different surface generation phenomena aforementioned.
152 citations
References
More filters
TL;DR: In this paper, the effect of several heat treatments on the microstructure and mechanical properties of Ti6Al4V processed by Selective Laser Melting (SLM) is studied.
1,320 citations
TL;DR: A review of published data on the mechanical properties of additively manufactured metallic materials can be found in this paper, where the additive manufacturing techniques utilized to generate samples covered in this review include powder bed fusion (eBM, SLM, DMLS) and directed energy deposition (eBF3).
Abstract: This article reviews published data on the mechanical properties of additively manufactured metallic materials. The additive manufacturing techniques utilized to generate samples covered in this review include powder bed fusion (e.g., EBM, SLM, DMLS) and directed energy deposition (e.g., LENS, EBF3). Although only a limited number of metallic alloy systems are currently available for additive manufacturing (e.g., Ti-6Al-4V, TiAl, stainless steel, Inconel 625/718, and Al-Si-10Mg), the bulk of the published mechanical properties information has been generated on Ti-6Al-4V. However, summary tables for published mechanical properties and/or key figures are included for each of the alloys listed above, grouped by the additive technique used to generate the data. Published values for mechanical properties obtained from hardness, tension/compression, fracture toughness, fatigue crack growth, and high cycle fatigue are included for as-built, heat-treated, and/or HIP conditions, when available. The effects of test...
1,093 citations
TL;DR: In this article, the authors compared two metal additive manufacturing processes, selective laser melting (SLM) and electron beam melting (EBM), based on microstructural and mechanical property evaluation of Ti6Al4V parts produced by these two processes.
Abstract: This work compares two metal additive manufacturing processes, selective laser melting (SLM) and electron beam melting (EBM), based on microstructural and mechanical property evaluation of Ti6Al4V parts produced by these two processes. Tensile and fatigue bars conforming to ASTM standards were fabricated using Ti6Al4V ELI grade material. Microstructural evolution was studied using optical and scanning electron microscopy. Tensile and fatigue tests were carried out to understand mechanical properties and to correlate them with the corresponding microstructure. The results show differences in microstructural evolution between SLM and EBM processed Ti6Al4V and their influence on mechanical properties. The microstructure of SLM processed parts were composed of an α′ martensitic phase, whereas the EBM processed parts contain primarily α and a small amount of β phase. Consequently, there are differences in tensile and fatigue properties between SLM- and EBM-produced Ti6Al4V parts. The differences are related to the cooling rates experienced as a consequence of the processing conditions associated with SLM and EBM processes.
705 citations
TL;DR: In this paper, a double optimization procedure of the process parameters is used to obtain a high quality material: firstly, the optimization of the initial process parameters for the minimization of inherent defects, and secondly, the optimisation of the further thermomechanical treatment to minimize internal stresses and adjust the microstructure.
496 citations
Book•
01 Jan 2006
TL;DR: In this paper, the authors present a review of materials fundamentals and a brief review of Materials Fundamentals and their applications in the field of composite composites, including metal matrix composites and composite adhesive bonding.
Abstract: Introduction Aluminium Magnesium & Beryllium Titanium High Strength Steels Superalloys Polymer Matrix Composites Adhesive Bonding and Integrally Cocured Structure Metal Matrix Composites Ceramic Matrix Composites Structural Assembly Appendix A: Metric Conversions Appendix B: Brief Review of Materials Fundamentals
460 citations