Abrasive Fluidized Bed (AFB) finishing of AlSi10Mg substrates manufactured by Direct Metal Laser Sintering (DMLS)

Atzeni, Eleonora; Barletta, Massimiliano; Calignano, Flaviana; Iuliano, Luca; Rubino, G.; Tagliaferri, V.

doi:10.1016/j.addma.2016.01.005

Cited by 49 publications

(22 citation statements)

References 19 publications

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“…This is the reason why it is also known as additive manufacturing (AM) [1]. By using different AM techniques, it is possible to obtain customized and complex components of different materials (metals, plastic or ceramic) with competitive costs and times [2]. In the aeronautic field, the most attractive materials are definitely metals, such as titanium and aluminum alloys, as they allow to design components with very complex shapes that are hardly obtained when using conventional technologies [2][3][4].…”

Section: Introductionmentioning

confidence: 99%

“…By using different AM techniques, it is possible to obtain customized and complex components of different materials (metals, plastic or ceramic) with competitive costs and times [2]. In the aeronautic field, the most attractive materials are definitely metals, such as titanium and aluminum alloys, as they allow to design components with very complex shapes that are hardly obtained when using conventional technologies [2][3][4]. Metal parts can be obtained using different AM techniques and are all based on power bed fusion (PBF) technology [1], such as electron beam melting (EBM) [5], direct metal laser sintering (DMLS) [4,6], and selective laser melting (SLM) [7,8].…”

Section: Introductionmentioning

confidence: 99%

“…However, the surfaces of the printed parts all have a low quality. The typical arithmetic average of the roughness profile (Ra) varies in the range 8-25 µm [2,6,9] depending on the adopted technology. Even if lower values of roughness are obtainable by laser sintering/melting, the EBM process is generally preferred for the production of aerospace components as it can produce high-quality products with excellent mechanical properties and fewer defects compared to those achieved by using laser technologies.…”

Section: Introductionmentioning

confidence: 99%

“…Nicoletto et al [12] studied the influence of roughness and morphology on the fatigue life of Ti alloy components produced with different orientations, using either a laser or an EBM system. Thus, the finishing of the AM parts is an important issue; different techniques can be adopted, such as abrasive fluidized bed [2], laser treatment [13][14][15][16], and chemical polishing [17][18][19]. Laser treatments offer some advantages compared to the other aforementioned techniques, such as absence of any mechanical contact due to the lack of tools which lead to a no wear high accuracy and high repeatability.…”

Section: Introductionmentioning

confidence: 99%

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Laser Finishing of Ti6Al4V Additive Manufactured Parts by Electron Beam Melting

Genna

Rubino

2019

Applied Sciences

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In this work, the feasibility of laser surface finishing of parts obtained by additive manufacturing (AM) was investigated. To this end, a 450 W fiber laser (operating in continuous wave, CW) was adopted to treat the surface of Ti-6Al-4V samples obtained via electron beam melting (EBM). During the tests, different laser energy densities and scanning speeds were used. In order to assess the quality of the treatment, either the as-built or the treated samples were analyzed by means of a three-dimensional (3D) profilometer, digital microscopy, and scanning electron microscopy. Analysis of variance (ANOVA) was performed to check which and how process parameters affected the finishing. The results show that, in the best conditions, the laser treatment reduced surface roughness by about 80%.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Laser Finishing of Ti6Al4V Additive Manufactured Parts by Electron Beam Melting

Genna

Rubino

2019

Applied Sciences

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“…Abrasive flow machining is an effective process of polishing metal-based AM parts with complex internal cavity and channel structures [7]. However, this method needs to design and control the flow channel for a specific target part, and problems such as the embedding of abrasives and the edge/corner rounding of the parts must be solved [13,14]. Therefore, it is important to exploit new solutions for AM part polishing whilst considering how to maintain the satisfactory geometry and application of the parts.The mechanical effects of ultrasonic power have been widely used in the removal of materials, such as in UltraSonic Machining (USM) technology.…”

mentioning

confidence: 99%

Material Removal in Ultrasonic Abrasive Polishing of Additive Manufactured Components

2019

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Featured Application: The study of the material removal mechanisms in ultrasonic abrasive polishing provides technical support for the surface modification of metal-based additive manufactured components which have poor surface quality. In addition, the technology can be further applied to smoothing various complex shapes and the internal features of both metal and non-metal parts, due to the use of loose abrasive particles and the possibility of uniform material removal process.Abstract: Powder-based layered Additive Manufacturing (AM) techniques lead to high surface roughness, due to the balling and partial melting of powders, which cannot satisfy the requirements of design and practical use. Consequently, until there is a significant step-change in the resolution of AM technology, finishing processes will be a necessary step in the additive manufacturing process. In this work, ultrasonic abrasive polishing experiments are conducted with the aim of improving the surface quality of additive manufactured components. The roles of cavitation bubbles and abrasive particles in material removal are discussed. The impact action of abrasive particles is simulated using the Smoothed Particle Hydrodynamics (SPH) method. The effects of ultrasonic output power and the concentration of abrasive suspension on machining characteristics are also examined. It is found that the cavitation bubble collapse in ultrasonic polishing can remove the partially melted structures efficiently, and further roughness improvement could be obtained using the micro-cut and impact of abrasive particles in the slurry. An increase in the ultrasonic output power and abrasive concentration within a certain range lead to a more desirable polishing effect.Additive Manufacturing (AM) technology has developed rapidly over the past two decades. Metal-based AM techniques represented by Powder Bed Fusion (PBF) have advantages, including the production of fine features with great geometrical accuracy and high-strength-to-weight ratios. However, its forming mechanism, based on the melting of metal powders, induces the agglomeration of partially melted powders and a balling phenomenon in the process [1]. Therefore, the average roughness (Ra) of metal-based AM parts is generally higher than 10 µm [2], which not only affects the appearance, but also greatly influences several functional properties, including fatigue resistance, friction performance and heat transfer [3][4][5]. Accordingly, post-process finishing is required to improve the surface quality of AM parts [6,7]. AM parts always have complex shapes and features, which makes the finishing process difficult. Several surface modification processes for AM parts have been reported in the literature. However, each process has limitations and complexities. Implementing hand polishing as one of the main finishing processes for AM parts would increase the labor cost and time, and the surface quality would be poor. Laser polishing, chemical polishing, electrochemical polishing, and abrasive flow polishing have s...

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Abrasive fluidized bed finishing to improve the fatigue behaviour of Ti6Al4V parts fabricated by electron beam melting

Atzeni

Rubino

Salmi

et al. 2020

Int J Adv Manuf Technol

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A study of the abrasive fluidized bed (AFB) finishing process was conducted to quantify the obtainable improvement of the fatigue behaviour of Ti6Al4V parts produced by electron beam melting (EBM). Axial-symmetric EBM samples were rotated at high speed inside a fluidized bed of stainless-steel media. The effects of the treatment time and the rotational speed on morphological features and fatigue life of the EBM samples were investigated. Outcomes showed that the improvement in surface properties induced by the AFB finishing process determined an increase up to 50% in fatigue life and a shift of the S-N curve.

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Abrasive Fluidized Bed (AFB) finishing of AlSi10Mg substrates manufactured by Direct Metal Laser Sintering (DMLS)

Cited by 49 publications

References 19 publications

Laser Finishing of Ti6Al4V Additive Manufactured Parts by Electron Beam Melting

Laser Finishing of Ti6Al4V Additive Manufactured Parts by Electron Beam Melting

Material Removal in Ultrasonic Abrasive Polishing of Additive Manufactured Components

Abrasive fluidized bed finishing to improve the fatigue behaviour of Ti6Al4V parts fabricated by electron beam melting

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