Journal ArticleDOI
Surface finishing of additively manufactured Inconel 625 complex internal channels: A case study using a multi-jet hydrodynamic approach
TLDR
In this paper, a multi-jet hydrodynamic approach was proposed to enhance the surface finish quality of the internal channels of a laser powder bed fusion (L-PBF) component.Abstract:
The surface roughness of components built using the laser powder bed fusion (L-PBF) process is poor. Surface finishing the internal channels of L-PBF components is a challenge. We propose a multi-jet hydrodynamic approach to enhance the surface finish quality of the internal channels. We investigate the hydrodynamic finishing on L-PBF Inconel 625 linear, stepped, and non-linear internal channels with diameters 5 to 1 mm and length up to 100 mm (replicating the geometries in rocket injectors, fuel nozzles, and cooling channels). The multi-jet hydrodynamic finishing approach improved the surface quality by 60–90 % (final Ra, Sa ≤ 1 μm and Rz, Sz ≤ 20 μm), using an abrasive concentration of ≤1 % in 15 min. of processing time. Areal surface texture parameters Sdr and roughness ratio r ≈1, evidenced the uniformity of the surface finish with dominant abrasive microcuts, regardless of the initial non-uniform additive manufactured surface. Most of the surface finished channels had excellent dimensional integrity and internal contour circularity. We then discussed the advancements required in metal additive manufacturing and internal surface finishing—to safely deploy L-PBF components with micro internal channels in fuel injection and fluid transfer applications.read more
Citations
More filters
Journal ArticleDOI
A review on the state-of-the-art of surface finishing processes and related ISO/ASTM standards for metal additive manufactured components
Jian-Yuan Lee,Jian-Yuan Lee,Arun Prasanth Nagalingam,Arun Prasanth Nagalingam,Swee Hock Yeo,Swee Hock Yeo +5 more
TL;DR: The current state-of-the-art metal additive manufacturing (AM) process still cannot meet the high industry requirements in terms of surface roughness as discussed by the authors, and there are limited ISO/ASTM standa...
Journal ArticleDOI
End to end process evaluation for additively manufactured liquid rocket engine thrust chambers
TL;DR: This paper provides a detailed literature review on the current state of theart, challenges, and opportunities for designing additively manufactured liquid rocket engines by means of laser powder bed fusion or powder-based and wire-based directed energy deposition (DED) techniques.
Journal ArticleDOI
Effect of Cut-Off, Evaluation Length, and Measurement Area in Profile and Areal Surface Texture Characterization of As-Built Metal Additive Manufactured Components
TL;DR: In this paper, a modified framework for surface texture characterization of AM components is proposed, where the maximum diameter (φm) of the surface asperities were determined through image processing and were used as cut-off for texture evaluation.
Journal ArticleDOI
A comprehensive literature review on laser powder bed fusion of Inconel superalloys
TL;DR: Inconel superalloys are one of the main classes of materials with good potential for production using the additive manufacturing process of laser powder bed fusion (PBF-LB), which has a broad range of applications in the transportation and energy sectors as mentioned in this paper .
Journal ArticleDOI
Multi-jet hydrodynamic surface finishing and X-ray computed tomography (X-CT) inspection of laser powder bed fused Inconel 625 fuel injection/spray nozzles
Arun Prasanth Nagalingam,Arun Prasanth Nagalingam,Jian-Yuan Lee,Jian-Yuan Lee,Swee Hock Yeo,Swee Hock Yeo +5 more
TL;DR: In this article, a multi-jet hydrodynamic cavitation abrasive finishing (MJ-HCAF) was used to surface finish the internal passages of direct metal laser sintered (DMLS) Inconel 625 fuel nozzles.
References
More filters
Book
Development of methods for the characterisation of roughness in three dimensions
TL;DR: In this article, an integrated approach to the assessment of 3D micro-topography is presented. Butler et al. present a detailed analysis of the effects of quantization on 3D topography characterisation.
Journal ArticleDOI
Surface roughness analysis, modelling and prediction in selective laser melting
TL;DR: In this paper, a new mathematical model is developed to include the presence of particles on top surfaces, in addition to the stair step effect, for the accurate prediction of surface roughness.
Journal ArticleDOI
Top surface and side roughness of Inconel 625 parts processed using selective laser melting
Kamran Mumtaz,Neil Hopkinson +1 more
TL;DR: In this article, the authors investigated the selective laser melting of Inconel 625 using an Nd:YAG pulsed laser to produce thin wall parts with an emphasis on attaining parts with minimum top surface and side surface roughness.
Journal ArticleDOI
Influences of processing parameters on surface roughness of Hastelloy X produced by selective laser melting
TL;DR: In this paper, the influence of processing parameters on surface roughness in Hastelloy X alloy was studied using an EOSINT M 280 machine and computer simulation was also used to understand thermal profiles at those two surfaces.
Journal ArticleDOI
Laser polishing of parts built up by selective laser sintering
TL;DR: In this paper, a surface finish method for parts built-up by selective laser sintering (SLS) is presented, where the laser beam melts a microscopic layer on the surface, which re-solidifies under shielding gas protective conditions, resulting in a smoother surface.