Novel multiphase jet polishing for complicated structured components produced by laser powder bed fusion

Feng, Junyuan; Zhang, Zhenyu; Shan-xin, YU; Chen, Xin; Wang, Dong; Gu, Qinming; Zhou, Chunchen; Zhang, Tianyu; Liu, Bingxin

doi:10.1016/j.addma.2023.103634

Cited by 4 publications

(5 citation statements)

References 29 publications

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“…Consequently, this phenomenon elucidates that defects located at the AGHP outlet also experience impacts of abrasive particles, resulting in material removal. Furthermore, our previous research findings propose a preferential removal of defects from the groove surface [47].…”

Section: Cfd Simulations Of the Aaj Polishing Process For The 2d And ...mentioning

confidence: 79%

A novel approach of jet polishing for interior surface of small-grooved components using three developed setups

Gu,

Zhang,

Zhou

et al. 2024

Int. J. Extrem. Manuf.

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It is a challenge to polish the interior surface of an additively manufactured component with complex structures and groove sizes less than 1 mm. Traditional polishing methods are disabled to polish the component, meanwhile keeping the structure intact. To overcome this challenge, small grooved components made of aluminum alloy with sizes less than 1 mm were fabricated by a custom-made printer. A novel approach of multi-phase jet polishing is proposed using a developed polisher, consisting of solid, liquid and gas phases. In comparison, an abrasive air jet polishing is suggested through a customized polisher, including solid and gas phases. After jet polishing, surface roughness (Sa) on the interior surface of grooves decreases from pristine 8.596 to 0.701 and 0.336 μm by abrasive air jet polishing and multi-phase jet polishing, respectively, and Sa reduces 92% and 96%, correspondingly. A formula is given out for the relationship between linear energy density and unit defect volume. The optimized parameters in additive manufacturing are that linear energy density varies from 0.135 to 0.22 J∙mm-1. Defect volume of unit area achieved by optimized parameters lessens 1/12 that of non-optimized ones. Computational fluid dynamics simulation reveals that material is removed by shear stress, and the alumina abrasives experience multiple collisions with the defects on the heat pipe groove, resulting in uniform material removal. This is in good agreement with the experimental results. The novel proposed setups, approach and findings provide new insights to manufacture complex-structured components, polish the small grooved structure, and keep it unbroken.

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Section: Cfd Simulations Of the Aaj Polishing Process For The 2d And ...mentioning

confidence: 79%

A novel approach of jet polishing for interior surface of small-grooved components using three developed setups

Gu,

Zhang,

Zhou

et al. 2024

Int. J. Extrem. Manuf.

Self Cite

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“…Therefore, the coupled Eulerian–Lagrangian approach (CEL) was applied in our new model. 22,46,47 In addition, it is worth noting that to evaluate the effect of different fluids on the polishing effect, a nonlinear constitution of the slurry was also considered in the model. In the mesoscale calculation results, the characteristic stress on the fibers and slurry was then extracted as the input boundary conditions for a smaller microscale abrasive model.…”

Section: Methodsmentioning

confidence: 99%

“…As a promising avenue, numerical simulation offers another direction to explore the CMP material-removal mechanism from different scales, mainly including finite element analysis (FEM), 19–21 computational fluid mechanics (CFD), 22–24 smooth particle hydrodynamics (SPH), 25–27 and molecular dynamics (MD). 28–31 Among these, the FEM, CFD, and SPH approaches mainly focus on the macro- and mesoscale aspects and the chemical reactions in CMP are not considered.…”

Section: Introductionmentioning

confidence: 99%

Atomic surface achieved through a novel cross-scale model from macroscale to nanoscale

Zhao,

Zhang,

Deng

et al. 2024

Nanoscale

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“…Like the cleaning results of the straight heat pipes, the weight loss of the PMMA abrasives is all higher than the PS abrasives. When the bent angle of the heat pipe increases from 0 • to 30 • (0 • means that the heat pipe is straight), the weight loss of both heat pipes increases, which is due to the increasing amount of printing defects during the printing of the structure in a larger tilt angle [22]. The cleaning results of the PMMA abrasive on the bent heat pipe are shown in Figure 9a-h.…”

Section: Plastic Abrasive Particles Are Used For the Treatment Effect...mentioning

confidence: 99%

“…After polishing, the average surface roughness of the inner wall was reduced from 1.05 µm to 0.212 µm. Feng et al [22] conducted an experimental study on a straight heat pipe with a length of 400 mm using a multiphase jet polishing method, which demonstrated the effectiveness of directly treating the inner wall of the pipe from the inlet jet.…”

Section: Introductionmentioning

confidence: 99%

Development of a Novel Water Jet Polisher Using Soft Abrasives for Small Complex-Structure Heat Pipes of Aluminum Alloy Produced Using Additive Manufacturing

Zhang,

Feng

et al. 2024

Materials

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It is a challenge to polish the interior surface of a small bent pipe with complex structures and sizes less than 0.5 mm. This is because of the fact that traditional polishing methods could destroy, block, or break the small complex structures. For a small bent pipe made of aluminum alloy produced using additive manufacturing, the defects, such as adhered powders and spatters, are easy to jam the pipe without polishing, possibly resulting in catastrophic failure for aerospace applications. To overcome this challenge, a novel water jet polisher was developed using soft polymethyl methacrylate (PMMA) abrasives. After polishing a specific area, the adhered powders on the interior surface were reduced from over 140 to 2, 3, and 6 by the soft abrasives with mesh sizes of 200, 400, and 600, respectively. The surface roughness Sa was decreased from 3.41 to 0.92 μm after polishing using PMMA abrasives with a mesh size of 200. In comparison, silica abrasives were also employed to polish the small bent pipes, leading to the bent part of pipes breaking. However, this kind of failure was absent when using soft abrasives. Computational fluid dynamics calculations elucidate that a peak erosion rate of silica abrasives for a bent pipe with a turn angle of 30° is 2.18 kg/(m2·s), which is 17 times that of soft abrasives. This is why the small bent pipe was broken using silica abrasives, whereas it remained intact when polished with soft abrasives. In addition, water jet polishing has a lower erosion rate, a relatively smooth erosion curve, and less erosion energy, leaving the bent parts intact. The developed soft abrasive water jet polisher and the findings of this study suggest new possibilities for cleaning the adhered powders and spatters and polishing the interior surface of small bent pipes with complex structures.

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Novel multiphase jet polishing for complicated structured components produced by laser powder bed fusion

Cited by 4 publications

References 29 publications

A novel approach of jet polishing for interior surface of small-grooved components using three developed setups

A novel approach of jet polishing for interior surface of small-grooved components using three developed setups

Atomic surface achieved through a novel cross-scale model from macroscale to nanoscale

Development of a Novel Water Jet Polisher Using Soft Abrasives for Small Complex-Structure Heat Pipes of Aluminum Alloy Produced Using Additive Manufacturing

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