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

Oliveira, Déborah de; Gomes, Milla Caroline; Santos, Aline Gonçalves dos; Ribeiro, Kandice Suane Barros; Vasques, Iago José; Coelho, Reginaldo Teixeira; Silva, Márcio Bacci da; Hung, Wayne

doi:10.1007/s40964-022-00325-3

Cited by 12 publications

(4 citation statements)

References 99 publications

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“…The automation technique is well established in subtractive manufacturing and is gaining ambience for the post processing of additive manufacturing parts too. In general, post processing techniques have been classified, as shown in Figure 14 , [ 156 ] with the three main subheadings derived from the energy used to create the polishing effect where the needs of post-processing techniques for AM metals increase [ 157 ].…”

Section: Intelligence In State-of-the-art Manufacturing Technology: M...mentioning

confidence: 99%

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Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

et al. 2023

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Additive manufacturing (AM), an enabler of Industry 4.0, recently opened limitless possibilities in various sectors covering personal, industrial, medical, aviation and even extra-terrestrial applications. Although significant research thrust is prevalent on this topic, a detailed review covering the impact, status, and prospects of artificial intelligence (AI) in the manufacturing sector has been ignored in the literature. Therefore, this review provides comprehensive information on smart mechanisms and systems emphasizing additive, subtractive and/or hybrid manufacturing processes in a collaborative, predictive, decisive, and intelligent environment. Relevant electronic databases were searched, and 248 articles were selected for qualitative synthesis. Our review suggests that significant improvements are required in connectivity, data sensing, and collection to enhance both subtractive and additive technologies, though the pervasive use of AI by machines and software helps to automate processes. An intelligent system is highly recommended in both conventional and non-conventional subtractive manufacturing (SM) methods to monitor and inspect the workpiece conditions for defect detection and to control the machining strategies in response to instantaneous output. Similarly, AM product quality can be improved through the online monitoring of melt pool and defect formation using suitable sensing devices followed by process control using machine learning (ML) algorithms. Challenges in implementing intelligent additive and subtractive manufacturing systems are also discussed in the article. The challenges comprise difficulty in self-optimizing CNC systems considering real-time material property and tool condition, defect detections by in-situ AM process monitoring, issues of overfitting and underfitting data in ML models and expensive and complicated set-ups in hybrid manufacturing processes.

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Section: Intelligence In State-of-the-art Manufacturing Technology: M...mentioning

confidence: 99%

Section: Figurementioning

confidence: 99%

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

et al. 2023

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“…This process improves the fatigue life and dimensional stability of the component. It is effective in reducing residual stresses in localized regions of the part, such as notches or critical stress-concentration areas [ 90 ]. Thermal stress relief is a post-processing technique that utilizes controlled heating and cooling to relieve residual stresses [ 25 ].…”

Section: Challenges In Multimetal Additive Manufacturingmentioning

confidence: 99%

Multimetal Research in Powder Bed Fusion: A Review

et al. 2023

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This article discusses the different forms of powder bed fusion (PBF) techniques, namely laser powder bed fusion (LPBF), electron beam powder bed fusion (EB-PBF) and large-area pulsed laser powder bed fusion (L-APBF). The challenges faced in multimetal additive manufacturing, including material compatibility, porosity, cracks, loss of alloying elements and oxide inclusions, have been extensively discussed. Solutions proposed to overcome these challenges include the optimization of printing parameters, the use of support structures, and post-processing techniques. Future research on metal composites, functionally graded materials, multi-alloy structures and materials with tailored properties are needed to address these challenges and improve the quality and reliability of the final product. The advancement of multimetal additive manufacturing can offer significant benefits for various industries.

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“…The production of heat pipes using additivie manufacturing has garnered considerable attention due to its advantages in processing complex and highly customizable parts, integrated manufacturing with structural components, lightweight design, and high processing efficiency [7][8][9][10][11]. Unfortunately, the surfaces of parts manufactured using additive manufacturing are accompanied by a large amount of scattered or slightly adhered powder, which significantly affects the surface quality of the printed parts and the practical stability of the heat pipe flow channel [12][13][14]. During the launch and maneuver of the space equipment, the influence of acceleration and thermal stress can lead to the falling off and aggregation of loose powders, which could potentially lead to channel blockage, resulting in a decline in the performance of the equipment and even the total failure of the overall device.…”

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

Cited by 12 publications

References 99 publications

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

Multimetal Research in Powder Bed Fusion: A Review

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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