Laser polishing of additively manufactured metal parts: a review

Manco, Emanuele; Cozzolino, Ersilia; Astarita, Antonello

doi:10.1080/02670844.2022.2072080

Cited by 20 publications

(9 citation statements)

References 100 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Laser processing is a promising technique to improve the performance of metal materials owing to their high laser input energy density as well as excellent spatial resolution [8][9][10][11]. Several laser surface modification techniques such as laser shock peening, laser remelting (LR), laser surface alloying and laser cladding (LC) have been developed.…”

Section: Introductionmentioning

confidence: 99%

Enhanced mechanical properties of molybdenum-coated aluminium via laser cladding

Zheng

Chen

2023

Surface Engineering

View full text Add to dashboard Cite

High-quality molybdenum coating has been successfully deposited on the pure aluminium substrate by high-velocity oxygen fuel spraying and subsequent laser remelting and laser cladding process. The microstructure, bonding strength, micro-hardness and wear resistance of the coating were systematically investigated. Results showed that the obtained coating exhibits a good metallurgical bonding interface as well as a dense microstructure with Al 8 Mo 3 , AlMo 3 and Al 5 Mo phases, which results in the significant improvement of the mechanical properties of the coating. The bonding strength is increased from 11 ± 1 to 57 ± 4 MPa after laser treatment. Micro-hardness of the coating (480 ± 30 HV) is observed to be increased by about 70% in comparison with the as-sprayed coating (281 ± 8 HV). The wear resistance of the Mo coating was also increased about five to six times by the laser remelting and cladding process.

show abstract

Section: Introductionmentioning

confidence: 99%

Enhanced mechanical properties of molybdenum-coated aluminium via laser cladding

Zheng

Chen

2023

Surface Engineering

View full text Add to dashboard Cite

show abstract

“…LP of metals is reported since the mid-2000s [ 5 , 6 ] and is considered by many industries as a conceivable alternative to the expensive and time-consuming standard polishing methods [ 2 ]. In recent times, LP has gained new interest as a way to improve the surface quality of samples produced by additive manufacturing (AM) [ 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 ]. Manco et al [ 7 ] and Annamaria et al [ 8 ] wrote two detailed reviews of this process for AM samples.…”

Section: Introductionmentioning

confidence: 99%

“…In recent times, LP has gained new interest as a way to improve the surface quality of samples produced by additive manufacturing (AM) [ 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 ]. Manco et al [ 7 ] and Annamaria et al [ 8 ] wrote two detailed reviews of this process for AM samples. Moreover, the LP process was investigated on the most common materials printed using an AM process; Obeidi et al [ 9 ] on 316 L stainless, Li et al [ 10 ] on Ti6Al4V, Yung et al [ 11 ] on CoCr, and Richter et al [ 12 ] on Co-Cr-Mo Alloy, and Dadbakhsh et al [ 13 ] on Inconel 718.…”

Section: Introductionmentioning

confidence: 99%

“…The principle of LP of metals is to melt a small volume of the material by a laser beam also known as the conduction regime. During the melting, the roughness is flattened due to the surface tension aided by increased mobility of the liquid state [ 2 , 3 , 7 , 8 , 9 , 11 , 17 ]. In addition, the LP process of metals can be divided into two categories that are related to the type of laser source; which are continuous wave (CW) or pulsed lasers [ 18 ].…”

Section: Introductionmentioning

confidence: 99%

“…In general, CW laser produces a large melt pool (10–80 µm deep) and so is employed for samples having significant roughness and it is referred to as macro-polishing. In contrast, the pulsed laser creates a very small melt pool (<5 µm deep) during each pulse and is utilized for samples with smaller roughness, and it is therefore referred to as micro-polishing [ 7 , 8 , 17 , 19 ]. In micro-polishing, the liquid state lasts, normally, shorter than the pulse repetition rate.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Optimization of Process Parameters for the Laser Polishing of Hardened Tool Steel

2022

View full text Add to dashboard Cite

In mold making, the mold surface roughness directly affects the surface roughness of the produced part. To achieve surface roughness below 0.8 μm, the cost of surface finish is high and time-consuming. One alternative to the different grinding and polishing steps is laser polishing (LP). This study investigates and models the LP of tool steel (X38CrMoV5-1-DIN 1.2343), typical for the mold industry, having an initial rough surface obtained by electrical discharge machining. The microstructures of the re-melted layer and heat-affected zone due to the LP process were also studied. Four parameters: the laser spot size, velocity, maximum melt pool temperature and overlapping were investigated via a design of experiments (DoE) approach, specifically a factorial design. The responses were line roughness (Ra), surface roughness (Sa), and waviness (Wa). The surface topography was measured before and after the LP process by white light profilometer or confocal microscopy. DoE results showed that the selected factors interact in a complex manner, including the interactions, and depend on the responses. The DoE analysis of the results revealed that the roughness is mainly affected by the velocity, temperature and overlap. Based on a first DoE model, an optimization of the parameters was performed and allowed to find optimum parameters for the LP of the rough samples. The optimum conditions to minimize the roughness are a spot size of 0.9 mm, a velocity of 50 mm/s, a temperature of 2080 °C and an overlap of 90%. By using these parameters, the roughness could be reduced by a factor of almost 8 from 3.8 µm to approximately 0.5 µm. Observations of the microstructure reveal that the re-melted layer consists of columnar grains of residual austenite. This can be explained by the carbon intake of the electro-machined surface that helps stabilize the austenitic phase.

show abstract

Energy saving in milling of electron beam–melted Ti6Al4V parts: influence of process parameters

Cozzolino

Astarita

2023

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Additive manufacturing (AM) is claimed to be a green technology because of its potential in improving material use efficiency. Electron beam melting (EBM) is among the most popular AM techniques adopted to manufacture titanium parts for medical and aerospace applications, as the technology offers an effective way of producing lightweight and complex parts. Nevertheless, additively manufactured parts hardly ever meet industrial quality standards, so post-treatments are always required resulting in additional resources and energy consumption. Moreover, still few works exist on joint analysis of energy consumption and roughness in milling EBMed parts by means of a non-typical tool, and this study aims to fill this gap of knowledge. Three EBM Ti6Al4V cylindrical samples were manufactured into a single job of the ARCAM A2X machine in the same process conditions. Three lengths, 120° apart from each other, were defined along the direction parallel to the axis of each cylinder to perform the milling by varying spindle speed, depth of cut, and machining speed. A high-performance complex-shaped insert has been used to perform the milling process to improve the surface finishing of the Ti6Al4V EBMed samples. Total energy consumption has been calculated as the sum of the machining time and the non-machining time. A joint investigation of both the surface roughness and the energy consumption in machining led to understanding which the best cut strategies are to perform milling with a complex cutting tool from a sustainability perspective. Results showed that it is not sustainable to choose the minimum depth of cut to obtain a fixed total depth of material removed as non-machining time showed to play a crucial role in the total energy consumption of the milling process.

show abstract

Laser polishing of additively manufactured metal parts: a review

Cited by 20 publications

References 100 publications

Enhanced mechanical properties of molybdenum-coated aluminium via laser cladding

Enhanced mechanical properties of molybdenum-coated aluminium via laser cladding

Optimization of Process Parameters for the Laser Polishing of Hardened Tool Steel

Energy saving in milling of electron beam–melted Ti6Al4V parts: influence of process parameters

Contact Info

Product

Resources

About