Influence of Postprocessing on Wear Resistance of Aerospace Steel Parts Produced by Laser Powder Bed Fusion

Abstract

The paper is devoted to the research of the effect of ultrasonic postprocessing—specifically, the effects of ultrasonic cavitation-abrasive finishing, ultrasonic plastic deformation, and vibration tumbling on surface quality, wear resistance, and the ability of real aircraft parts with complex geometries and with sizes less than and more than 100 mm to work in exploitation conditions. The parts were produced by laser powder bed fusion from two types of anticorrosion steels of austenitic and martensitic grades—20Kh13 (DIN 1.4021, X20Cr13, AISI 420) and 12Kh18N9T (DIN 1.4541, X10CrNiTi18-10, AISI 321). The finishing technologies based on mechanical action—plastic deformation, abrasive wear, and complex mechanolysis showed an effect on reducing the submicron surface roughness, removing the trapped powder granules from the manufactured functional surfaces and their wear resistance. The tests were completed by proving resistance of the produced parts to exploitation conditions—vibration fatigue and corrosion in salt fog. The roughness arithmetic mean deviation Ra was improved by 50–52% after cavitation-abrasive finishing, by 28–30% after ultrasonic plastic deformation, and by 65–70% after vibratory tumbling. The effect on wear resistance is correlated with the improved roughness. The effect of used techniques on resistance to abrasive wear was explained and grounded.

Influence of Cold Work on the Efficiency of Vibratory Machining

“…Based on the data contained in Table 1 and literature [4,9,11], it can be confirmed that vibratory machining results in an isotropic structure.…”

“…Vibratory machining is a finishing process based on chemicalmechanical surface treatment [11,12]. The type of media usedshapes -determines the nature of the process: deburring, grinding or polishing.…”

Simulation of Mechanical and Thermal Loads and Microtexturing of Ceramic Cutting Inserts in Turning a Nickel-Based Alloy

“…• the presence of microcracks due to the shrinkage of the molten material as it solidifies [22,23]; • the presence of surface morphology subjected to repeated focal overheating with the creation of near-track/weld stress zones (heat-affected zones) [24,25]; • active evaporation of the lightest materials from the processing zone [26,27]; • formation of a transitional nanoporous interlayer consisting of more refractory material components [28,29]; • increased formation of brittle structures in the near-surface layer (the formation of second-order secondary compounds on the heating surface, due to the material's active oxidation as a result of the interaction of the molten material of the cutting insert/substrate and coating with the environment) [30]; • splashing of material from the processing zone due to thermal shock [31,32].…”

Characterization of LPBF Produced Fe2.9wt.%Si for Electromagnetic Actuator

“…The potential applications of LPBF are vast and diverse. In aerospace, for example, the technique can be used to produce lightweight components with complex geometries, reducing the weight of aircraft and improving fuel efficiency [17,18,19,20]. In the medical industry, LPBF can be used to produce customized implants and prosthetics with enhanced biocompatibility [21,22,23,24].…”