Surface modification of additive manufactured components by ultrasonic cavitation abrasive finishing
Tan, Kai Liang
Yeo, Song Huat
Date of Issue2017
School of Mechanical and Aerospace Engineering
Rolls-Royce@NTU Corporate Lab
Powder Bed Fusion (PBF) is a group of powder-bed based layered Additive Manufacturing (AM) techniques for direct fabrication of metal and metal alloys. Despite its advancements, the surface quality of as-built PBF components remains unsatisfactory. In this paper, a new post-process finishing technique, based on ultrasonic cavitation effects in a solid-liquid mixture, is introduced for PBF-built components. Trials were conducted on side surfaces of Inconel 625 manufactured by Direct Metal Laser Sintering (DMLS). Results have demonstrated that this technique improves Ra values of as-built Inconel 625 side surfaces by up to 45% after 30 min of processing time. Scanning electron microscopic images revealed that most small-sized partially melted powders were removed through heterogeneous cavitation nucleation on the specimens’ rough initial surface. A secondary fine-scale erosion mechanism by micro-abrasives, accelerated by cavitation bubble collapses, further depressed difficult-to-remove irregularities.
Ultrasonic Cavitation Abrasive Finishing
© 2017 Elsevier B.V. This is the author created version of a work that has been peer reviewed and accepted for publication by Wear, © 2017 Elsevier B.V. It incorporates referee’s comments but changes resulting from the publishing process, such as copyediting, structural formatting, may not be reflected in this document. The published version is available at:[http://dx.doi.org/10.1016/j.wear.2017.02.030].