Advances in polishing of internal structures on parts made by laser-based powder bed fusion

doi:10.1007/s11465-022-0724-0

Front. Mech. Eng.

2023, Vol. 18

Issue (1) : 8 https://doi.org/10.1007/s11465-022-0724-0

REVIEW ARTICLE

Advances in polishing of internal structures on parts made by laser-based powder bed fusion

Mingyue SHEN¹, Fengzhou FANG^1,²(

)

¹. Centre of Micro/Nano Manufacturing Technology, University College Dublin, Dublin 4, Ireland
². State Key Laboratory of Precision Measuring Technology and Instruments, Laboratory of Micro/Nano Manufacturing Technology, Tianjin University, Tianjin 300072, China

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Abstract

The internal structures of metallic products are important in realizing functional applications. Considering the manufacturing of inner structures, laser-based powder bed fusion (L-PBF) is an attractive approach because its layering principle enables the fabrication of parts with customized interior structures. However, the inferior surface quality of L-PBF components hinders its productization progress seriously. In this article, process, basic forms, and applications relevant to L-PBF internal structures are reviewed comprehensively. The causes of poor surface quality and differences in the microstructure and property of the surface features of L-PBF inner structures are presented to provide a perspective of their surface characteristics. Various polishing technologies for L-PBF components with inner structures are presented, whereas their strengths and weaknesses are summarized along with a discussion on the challenges and prospects for improving the interior surface quality of L-PBF parts.

Keywords laser-based powder bed fusion polishing internal structures surface quality surface features post process additive manufacturing

Corresponding Author(s): Fengzhou FANG

About author: Changjian Wang and Zhiying Yang contributed equally to this work.

Just Accepted Date: 23 August 2022 Issue Date: 02 March 2023

Cite this article:

Mingyue SHEN,Fengzhou FANG. Advances in polishing of internal structures on parts made by laser-based powder bed fusion[J]. Front. Mech. Eng., 2023, 18(1): 8.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-022-0724-0
https://academic.hep.com.cn/fme/EN/Y2023/V18/I1/8

Tab.1 Classification of various LAM processes

Fig.1 Schematic of the L-PBF apparatus. L-PBF: laser-based powder bed fusion.

Fig.2 Various laser-based powder bed fusion tubes: (a) straight, (b) horizontal T-shape, (c) vertical T-shape, and (d) reduction of size [47]. Reprinted with permission from Ref. [47] from Springer Nature.

Fig.3 Computer-aided design models of uniform (left) and graded density (right) lattice structures [51]. Reproduced with permission from Ref. [51] from Elsevier.

Fig.4 Part images: (a) fuel nozzle with internal channel from the General Electric Company [66], (b) ejector side (orange) and injector side (blue) of mold with incorporated conformal cooling channels near to cavity [67], and (c) as built face center cube, vertex cube, and edge center cube structures [68] that prepared by laser-based powder bed fusion. Reproduced with permission from Ref. [68] from Elsevier.

Fig.5 Laser-based powder bed fusion parts (top) and their computer-aided design models (bottom) combined with different forms of internal structures: (a) cylinder with honeycomb inner structure and two spiral channels from 316L stainless steel, (b) conical frustum object with ribs and one spiral inner channel from 904L stainless steel, and (c) heat exchanger with complex cooling channels from Inconel 625 [74]. Reprinted with permission from Ref. [74] from Elsevier.

Fig.6 Schematic of the different types of laser-based powder bed fusion surfaces according to their printing orientations [79]. Reproduced with permission from Ref. [79] from Elsevier.

Fig.7 Schematic of the crystallization solidification of molten pools during laser-based powder bed fusion process: (a) single molten pool, (b) “layer–layer” molten pool boundaries (MPB), and (c) “track–track” MPB. The arrows represent the grain orientations [23]. Reproduced with permission from Ref. [23] from Elsevier.

Fig.8 Scanning electron microcopy images of (a) 5° inclined surface [15] and (b) an inclined sample with staircase effect clearly visible [16]. Reproduced with permissions from Refs. [15,16] from Elsevier.

Fig.9 Scanning electron microcopy images of balling characteristics with different oxygen contents during laser-based powder bed fusion: (a) 0.1%, (b) 2%, and (c) 10% [82]. Reproduced with permission from Ref. [82] from Springer Nature.

Fig.10 Optical images of cross-sectional [85]: (a) bulk AlSi7Mg microstructure, (b) balling on the surface, and (c) partially melted spatters with spherical morphology on the surface. The arrow in (a) shows the build direction. Reproduced with permission from Ref. [85] from Elsevier.

Fig.11 Morphologies of etched cross-sections on raw laser-based powder bed fusion [86]: (a) top cross-section 1, (b) top cross-section 2, (c) face up, (d) side, and (e) face down surfaces.

Fig.12 Morphologies of (a) polished, (b) etched cross-section, (c) high magnification of etched cross-section at position I; (d) polished, (e) etched cross-section, and (f) high magnification of etched cross-section at position II in Fig. 11(d) [86].

Fig.13 Data graphs of face up and face down surface roughness of laser-based powder bed fusion Hastelloy X samples with different printing inclinations (45° to 90°) [87]. Reproduced with permission from Ref. [87] from Elsevier.

Fig.14 Different types of surfaces of (a) a laser-based powder bed fusion straight channel with its cross-sectional optical micrograph [71], (b) a unit cell of BCC lattice structure, and (c) the top view of the laser-based powder bed fusion BCC lattice structures [89]. BCC: body-centered cubic. Reproduced with permission from Ref. [71] from Elsevier.

Fig.15 Schematic of (a) abrasive flow machining [106] and (b) magnetic abrasive finishing [107]. Reproduced with permissions from Refs. [106,107] from Elsevier.

Fig.16 Scanning electron microcopy images of interior channel morphology before and after electropolishing of horizontal channel and vertical channel walls [123]. Reproduced with permission from Ref. [123] from Elsevier.

Fig.17 Schematic of HCAF apparatus [12]. HCAF: hydrodynamic cavitation abrasive finishing. Reproduced with permission from Ref. [12] from Elsevier.

Tab.2 List of polishing methods, materials, polishing time, and surface roughness before and after the polishing of L-PBF internal structures [1,8,9,11,107,127,128]

Fig.18 Part images of (a) quantitative results showing diameter removal differences at different positions of a laser-based powder bed fusion channel after two-way AFM [110], (b) surface topography of laser-based powder bed fusion channel before and after HCAF process [128], and (c) morphology comparison of laser-based powder bed fusion body-centered cubic lattice structures before and after electrochemical polishing (ECP) and overpotential electrochemical polishing (OECP) [9]. AFM: abrasive flow machining, HCAF: hydrodynamic cavitation abrasive finishing. Reproduced with permissions from Refs. [110,128] from Emerald Publishing Limited and Elsevier, respectively.

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