Investigation on pulsed electrolytically polished AlSi10Mg alloy processed via selective laser melting technique

2021 ◽  
pp. 146442072110453
Author(s):  
S. Anand Kumar ◽  
Anigani Sudarshan Reddy ◽  
Snehith Mathias ◽  
Abhishek Shrivastava ◽  
Prasad Raghupatruni
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Selective Laser Melting ◽  
Surface Integrity ◽  
Current Density ◽  
Aluminium Alloys ◽  
Surface Finishing ◽  
Laser Melting ◽  
X Ray ◽  
Ratio Curve

Currently, the surface integrity-related issues of additively manufactured parts are limiting the potential high-end applications. The present work investigates the effectiveness of the pulsed-electropolishing technique to improve the surface integrity of aluminium alloys fabricated using the selective laser melting (SLM) technique. Due to its low density, high corrosion resistance, the aluminium alloys considerably enhance the performance of lightweight critical parts for different industrial applications. In this study, selective laser melted AlSi10Mg samples were subjected to microstructural examinations using optical microscopy, scanning electron microscopy, energy-dispersive X-ray spectroscopy and X-ray diffraction technique. The microhardness and tensile properties were determined using a microhardness tester and a universal testing machine, respectively. The pulsed-electropolishing process was employed for the surface finishing of the SLM-processed AlSi10Mg samples. The effect of current density on the electropolishing of selective laser melted AlSi10Mg alloy were also investigated. The microstructures of printed samples revealed a density of greater than 99.9% and weld beads along the build direction (longitudinal) and laser scan paths perpendicular to the build direction (transverse). The microhardness, yield and tensile strength properties were similar in both as-printed conditions. The pulsed electropolishing results showed a beneficial effect of higher current density values, resulting in decreased surface roughness of the SLM-processed AlSi10Mg samples. Compared to as-printed conditions, a significant decrease in surface roughness of about ∼73.35% under optimized electropolishing conditions was noted. The material ratio curve shows that the surface topography becomes more uniform with increased current density and has lesser surface undulations for as-printed samples. The 2D line profilogram and 3D surface topography of electropolished SLM-processed samples reveal the surface finish quality characteristics. The material ratio curve aids as an effective method to assess and qualify the surface topography of electropolished samples.

scholarly journals Study on Magnetic Abrasive Finishing Process of AlSi10Mg Alloy Curved Surface Formed by Selective Laser Melting

2021 ◽  
Author(s):  
Yuntao Cui ◽  
Guixiang Zhang ◽  
Tonglei Cui ◽  
Peixin Zhu ◽  
Jiajing Du ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Permanent Magnet ◽  
Selective Laser Melting ◽  
Surface Hardness ◽  
Curved Surface ◽  
Surface Finishing ◽  
Laser Melting ◽  
Surface Sample ◽  
Surface Samples ◽  
Finishing Tool

Abstract In this paper, AlSi10Mg alloy powder is selected as the forming powder of Selective Laser Melting technology, and the AlSi10Mg alloy SLM curved surface sample is constructed by setting the internal and external layering parameters. In view of the relatively rough surface roughness of SLM technology molded parts, this paper selects the magnetic finishing technology with higher flexibility characteristics to perform surface finishing and finishing on the formed curved surface samples. Explore the feasibility of magnetic finishing technology on the finishing of SLM shaped curved parts, and test and analyze the surface roughness, surface hardness and hydrophobicity of the finishing permanent magnet tools and the curved surface samples before and after finishing. Finally, it was found that the use of a 75° trapezoidal slotted permanent magnet finishing tool to absorb spherical Al2O3 magnetic abrasives for flexible finishing of AlSi10Mg alloy SLM shaped curved surface samples can achieve better finishing results.In this paper, the orthogonal experiment method is used to optimize the finishing experiment. It is found that the finishing parameters of the spindle speed is 1800 r/min, the feed rate is 5 mm/min, the gap is 2 mm, and the abrasive consumption is 7g to form the AlSi10Mg alloy SLM. The surface roughness Ra=0.279μm can be obtained by magnetic finishing of the curved sample, and the surface morphology of the sample has been greatly improved. At the same time, it is found that the magnetic finishing technology improves the surface roughness of the AlSi10Mg alloy SLM forming surface sample, while it does not change the surface hardness of the sample, but it can significantly improve the hydrophobicity of the sample surface.

scholarly journals Improving surface quality in selective laser melting based tool making

2021 ◽  
Author(s):  
Filippo Simoni ◽  
Andrea Huxol ◽  
Franz-Josef Villmer
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Selective Laser Melting ◽  
Melting Process ◽  
Laser Remelting ◽  
Laser Melting ◽  
Great Cost ◽  
Starting Point ◽  
Processing Techniques

AbstractIn the last years, Additive Manufacturing, thanks to its capability of continuous improvements in performance and cost-efficiency, was able to partly replace and redefine well-established manufacturing processes. This research is based on the idea to achieve great cost and operational benefits especially in the field of tool making for injection molding by combining traditional and additive manufacturing in one process chain. Special attention is given to the surface quality in terms of surface roughness and its optimization directly in the Selective Laser Melting process. This article presents the possibility for a remelting process of the SLM parts as a way to optimize the surfaces of the produced parts. The influence of laser remelting on the surface roughness of the parts is analyzed while varying machine parameters like laser power and scan settings. Laser remelting with optimized parameter settings considerably improves the surface quality of SLM parts and is a great starting point for further post-processing techniques, which require a low initial value of surface roughness.

scholarly journals Directionally-Dependent Mechanical Properties of Ti6Al4V Manufactured by Electron Beam Melting (EBM) and Selective Laser Melting (SLM)

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3603
Author(s):  
Tim Pasang ◽  
Benny Tavlovich ◽  
Omry Yannay ◽  
Ben Jakson ◽  
Mike Fry ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Tensile Strength ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Electron Beam Melting ◽  
Rolling Direction ◽  
Laser Melting ◽  
Plate Rolling

An investigation of mechanical properties of Ti6Al4V produced by additive manufacturing (AM) in the as-printed condition have been conducted and compared with wrought alloys. The AM samples were built by Selective Laser Melting (SLM) and Electron Beam Melting (EBM) in 0°, 45° and 90°—relative to horizontal direction. Similarly, the wrought samples were also cut and tested in the same directions relative to the plate rolling direction. The microstructures of the samples were significantly different on all samples. α′ martensite was observed on the SLM, acicular α on EBM and combination of both on the wrought alloy. EBM samples had higher surface roughness (Ra) compared with both SLM and wrought alloy. SLM samples were comparatively harder than wrought alloy and EBM. Tensile strength of the wrought alloy was higher in all directions except for 45°, where SLM samples showed higher strength than both EBM and wrought alloy on that direction. The ductility of the wrought alloy was consistently higher than both SLM and EBM indicated by clear necking feature on the wrought alloy samples. Dimples were observed on all fracture surfaces.

scholarly journals Selective laser melting for improving quality characteristics of a prism shaped topology injection mould tool insert for the automotive industry

2021 ◽  
pp. 095440622198938
Author(s):  
Mennatallah F El Kashouty ◽  
Allan EW Rennie ◽  
Mootaz Ghazy ◽  
Ahmed Abd El Aziz
Keyword(s):  
Surface Roughness ◽  
Selective Laser Melting ◽  
Automotive Industry ◽  
Injection Moulding ◽  
Dimensional Accuracy ◽  
Quality Characteristics ◽  
Surface Topology ◽  
Laser Melting ◽  
Injection Mould ◽  
Tool Insert

Manufacturing process constraints and design complexities are the main challenges that face the aftermarket automotive industry. For that reason, recently, selective laser melting (SLM) is being recognised as a viable approach in the fabrication of injection moulding tool inserts. Due to its versatility, SLM technology is capable of producing freeform designs. For the first reported time, in this study SLM is recognized for its novel application in overcoming fabrication complexities for prism shaped topology of a vehicle headlamp’s reflector injection moulding tool insert. Henceforth, performance measures of the SLM-fabricated injection mould tool insert is assessed in comparison to a CNC-milled counterpart to improve quality characteristics. Tests executed and detailed in this paper are divided into two stages; the first stage assesses both fabricated tool inserts in terms of manufacturability; the second stage assesses the functionality of the end-products by measuring the surface roughness, dimensional accuracy and light reflectivity from the vehicle reflectors. The results obtained show that employing SLM technology can offer an effective and efficient alternative to subtractive manufacturing, successfully producing tool inserts with complex surface topology. Significant benefits in terms of surface roughness, dimensional accuracy and product functionality were achieved through the use of SLM technology. it was concluded that the SLM-fabricated inserts products proved to have relatively lower values of surface roughness in comparison to their CNC counterparts.

scholarly journals Investigation on Selective Laser Melting AlSi10Mg Cellular Lattice Strut: Molten Pool Morphology, Surface Roughness and Dimensional Accuracy

Materials ◽  
2018 ◽  
Vol 11 (3) ◽  
pp. 392 ◽  
Author(s):  
Xuesong Han ◽  
Haihong Zhu ◽  
Xiaojia Nie ◽  
Guoqing Wang ◽  
Xiaoyan Zeng
Keyword(s):  
Surface Roughness ◽  
Selective Laser Melting ◽  
Molten Pool ◽  
Dimensional Accuracy ◽  
Laser Melting

X-ray CT analysis of the influence of process on defect in Ti-6Al-4V parts produced with Selective Laser Melting technology

2019 ◽  
Vol 106 (1-2) ◽  
pp. 3-14 ◽  
Author(s):  
Xin Zhou ◽  
Ning Dai ◽  
Mingqiang Chu ◽  
Lei Wang ◽  
Dawei Li ◽  
...  
Keyword(s):  
Selective Laser Melting ◽  
Laser Melting ◽  
X Ray ◽  
Melting Technology ◽  
Ct Analysis

Influence of selective laser melting scanning speed parameter on the surface morphology, surface roughness, and micropores for manufactured Ti6Al4V parts

2020 ◽  
Vol 35 (15) ◽  
pp. 2025-2035
Author(s):  
Mohd Faizal Sadali ◽  
Mohamad Zaki Hassan ◽  
Fauzan Ahmad ◽  
Hafizal Yahaya ◽  
Zainudin A Rasid
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Selective Laser Melting ◽  
Scanning Speed ◽  
Laser Melting ◽  
Speed Parameter ◽  
Image Position

Abstract

Sign in / Sign up

Export Citation Format

Share Document