Surface roughness is gaining increasing recognition in the processing design methods of additive manufacturing (AM) due to its role in many critical applications. This impact extends not only to various AM product manufacturing but also to indirect applications, such as molding and casting. This review article discusses the role of processing on the surface roughness of AM-printed polymers with limited post-processing by summarizing recent advances. This review offers a benchmark for surface quality improvement of AM processes, considering the surface roughness of polymeric parts. For this purpose, it lists and analyzes the key processes and various printing parameters used to monitor and adjust surface roughness under given constraints. Four AM techniques for manufacturing polymeric parts are compared: fused filament fabrication (FFF), selective laser sintering (SLS), vat photopolymerization (VPP), and material jetting (MJT). A review and discussion of recent studies are presented, along with the most critical process parameters that affect surface roughness for the selected AM techniques. To assist in selecting the most appropriate method of 3D printing, comparable research summaries are presented. The outcome is a detailed survey of current techniques, process parameters, roughness ranges, and their applicability in achieving surface quality improvement in as-printed polymers.

Material jetting (MJT) is a recognized additive manufacturing (AM) method to combine various materials and create a wide range of designed appearances. However, the measured color of MJT objects is frequently different from the color provided in the printer software. As a result, estimating the color quality and the measured color attributes of an object before printing is vital for accurate color reproduction. This study investigates the color variation based on the texture in an object 3D-printed using the MJT method on a rotary tray. The novel radial shape of the rotary tray build platform and variation in the layers structure were targeted as the main factors that can increase the uncertainty in accurate color reproduction. The influence of the PolyJet printer setup has been examined by thickness variation of the colored layers, location on the tray (swath selection), ink color, and finish type between layers. Color quality was assessed by comparing the produced object color by calculating spectral and colorimetric differences. Spearman rank correlation coefficient and principal component analysis (PCA) methods were used to analyze the direct or indirect influence of independent categorical factors on the measured color variables. Based on the studied parameters, switching swathes did not fail printer objects for industrial color matching. In contrast, a thickness variation as small as 0.5 mm could cause CIEDE2000 above 5 for most models, resulting in unnatural color reproduction. Color differences in most objects might be discernible to inexperienced observers, depending on the 3D printing parameters.

Understanding the role of nanoparticles in magnesium (Mg)‐based materials and protective coating provides valuable information to achieve an optimized combination of mechanical and corrosion protection properties of Mg nanocomposites. The present study investigates the effects of SiC nanoparticles on the corrosion behavior and structure of Mg‐SiC composites substrates coated by plasma electrolytic oxidation (PEO). Moreover, the influence of different volume fractions of SiCn up to 10% on corrosion behavior and galvanic reactions between Mg matrix and SiC particles was also investigated. The morphology, distribution of the phases, and the microstructure of the coating were characterized by SEM, EDAX, X‐ray photoelectron spectroscopy, and XRD. The corrosion resistance of the samples was determined through dynamic polarization and electrochemical impedance spectroscopy tests before and after PEO coating treatment. The results indicate that the Mg nanocomposite with 1 vol% SiCn (M1Sn) coated by PEO coating shows higher corrosion resistance than the samples with a higher percentage of SiCn, as well as the sample without SiCn particles.

Environmentally friendly anti-corrosion surface treatment reinforced by nano-ceramic metal oxide particles were developed as a protective layer for galvanized steel. The treatment bath is based on a nano-ceramic conversion coating composed of dilute hexafluorozirconic acid with small quantities of additive components containing H2O2. The corrosion resistance of treated substrate was compared to samples treated in phosphate conversion coating bath and in a hexafluorozirconic acid without the addition. The effect of other parameters such as pH solution and H2O2 concentration as oxidant on coating morphology were evaluated. Scanning electron microscopy/energy dispersive spectroscopy(SEM/EDS) was used to characterize the coating surface morphology. Utilizing DC polarization and salt spray test were performed on the treated substrate for studying the corrosion performance of the coatings. During surface examination, uniform distribution of Zr along the surface of all treated samples was observed. Results of corrosion tests showed that phosphate-free coating have a higher corrosion resistance than simple galvanized steel samples and provided long term corrosion performance comparable to that of phosphate. 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