Abrasive and non-conventional post-processing techniques to improve surface finish of additively manufactured metals: a review

Author(s)

De Oliveira, Deborah ; Gomes, Milla Caroline ; Dos Santos, Aline Goncalves ; Barros Ribeiro, Kandice Suane ; Vasques, Iago Jose ; Coelho, Reginaldo Teixeira ; Da Silva, Marcio Bacci ; Hung, Nguyen Wayne

• Document type: Journal article
• Source: PROGRESS IN ADDITIVE MANUFACTURING; v. N/A, p. 18-pg., 2022-07-21.

Abstract

Metal additive manufacturing (MAM) has attracted global industry and academia due to its flexibility and ability to achieve complex geometry. The inherent rough surfaces are of concerns and need to be addressed to meet the strict requirement of critical engineering components. This paper reviews the working principles for common MAM processes and summarizes current post-processing techniques for surface finish improvement. Relevant finishing techniques using abrasives and non-conventional techniques, such as grinding, polishing, laser, peening, buffing, and electrochemical polishing are reviewed, and typical results are documented for different AM processes. Limitation of each process and enhancing techniques using magnetism, ultrasonic, and pulsed current for selected processes are presented. Post processing not only reduces surface roughness, but also contributes to dimensional and form tolerances, and prolongs long-term fatigue and creep life of AM metals. Although post-processing techniques can effectively remove surface defects to achieve submicron surface finish, controlling of surface defects that extend deeply below a surface is still a challenge. Future hybrid system that combines AM and a non-traditional post-process would meet the requirement for MAM. (AU)

• FAPESP's process: 19/08926-6 - Advanced post processing for quality enhancement of 3D-printed engineering components
• Grantee: Reginaldo Teixeira Coelho
• Support Opportunities: Regular Research Grants
• FAPESP's process: 19/00343-1 - Control of directed energy deposition process for manufacturing complex geometry components by Additive Manufacturing (AM)
• Grantee: Kandice Suane Barros Ribeiro
• Support Opportunities: Scholarships in Brazil - Doctorate
• FAPESP's process: 16/11309-0 - The study, development and application of a hybrid process: Additive Manufacturing (AM) plus High Speed Machining/Grinding (HSM/G)
• Grantee: Reginaldo Teixeira Coelho
• Support Opportunities: Research Projects - Thematic Grants
• FAPESP's process: 20/03110-5 - Characterization of WC-Co deposited through additive manufacturing (AM) using the Direct Energy Deposition (DED) method
• Grantee: Gabriel Viana Figueiredo
• Support Opportunities: Scholarships in Brazil - Scientific Initiation