Electrochemical-Based Surface Enhancement of Additively Manufactured Ti-6Al-4V Complex Structures

Fayazfar, Haniyeh; Rishmawi, Issa; Vlasea, Mihaela

doi:10.1007/s11665-021-05512-x

Cited by 12 publications

(22 citation statements)

References 32 publications

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“…Considering that AM parts generally hold many intricate details and unreachable narrow spaces, this factor could further complicate the effective treatment of such parts and lead to a non-uniform polishing effect. 169 Moreover, some studies have concluded that the excessive build-up of heat and polishing products are responsible for the inferior surface quality of the internal spaces after electropolishing. 131,150,169 It has also been argued that the difficulty of achieving a uniform surface finish for AM parts by electropolishing stems from their heterogeneous microstructure.…”

Section: Cocrmentioning

confidence: 99%

“…169 Moreover, some studies have concluded that the excessive build-up of heat and polishing products are responsible for the inferior surface quality of the internal spaces after electropolishing. 131,150,169 It has also been argued that the difficulty of achieving a uniform surface finish for AM parts by electropolishing stems from their heterogeneous microstructure. 170 On one hand, during the AM fabrication process, each part of the microstructure may experience a different history of melting, solidification, and subsequent heating and cooling cycles.…”

Section: Cocrmentioning

confidence: 99%

“…Additionally, prolonged treatment times impose cost and sustainability issues such as higher energy consumption, longer use of the equipment, and disposal of highly contaminated waste to the environment. 169 A better solution is the usage of low conductivity electrolytes to increase the voltage gradient between the peaks and valleys of a rough surface with large asperities and accelerate their selective dissolution. Likewise, highly viscous solutions can be used to focus the electric field on the small asperities and enhance their preferential removal during diffusion-controlled dissolution.…”

Section: Cocrmentioning

confidence: 99%

“…They employed an off-time of 10 s as well as electrolyte agitation for refreshing the electrolyte and discharging the polishing products from the part's surface. Fayazfar et al 169 followed the same path by using a combination of agitation and pulsed current for electropolishing of inner spaces in AM Ti-6Al-4V parts.…”

Section: Future Research Avenuementioning

confidence: 99%

“…Potential approaches for controlling material removal over the entire AM part.-An ideal surface treatment for AM parts would effectively enhance their surface quality with minimal weight loss. 121,169 Nowadays, 3D design software offers options similar to a feedback loop where the fabrication-induced distortions can be predicted by simulation and compensated by a corrected geometry to fabricate a more accurate part. A similar approach can be employed where the dimensional changes needed for the achievement of the target surface finish can be predicted and compensated in the design stage.…”

Section: Future Research Avenuementioning

confidence: 99%

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Review—Electropolishing of Additive Manufactured Metal Parts

Chaghazardi

Wüthrich

2022

J. Electrochem. Soc.

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Most metal additive manufacturing (AM) technologies are rapidly approaching, and in some cases even exceeding, the Technology Readiness Level 8, indicating that they are widely available and capable of completing a wide range of projects despite identified process restrictions. Thanks to significant technological progress made in the last decade, more industries are incorporating metal AM in their production processes to obtain highly customized parts with complex geometries. However, the poor surface finish of AM parts is a major drawback to their aesthetics and functionality. Over the years, different approaches were proposed to enhance surface quality, each bearing its limitations. Among the proposed technologies, electropolishing is a strong candidate for improving the surface finish of AM parts. Here we review the literature on electropolishing of AM parts, and, to provide a comprehensive study of the different aspects involved, the origin and consequences of the surface properties of AM parts as well as an evaluation of other available post-treatment technologies. Finally, the existing challenges on the way and potential countermeasures to expedite the industrial application of the electropolishing process for post-treatment of AM parts as well as future research avenues are discussed.

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Section: Cocrmentioning

confidence: 99%

Section: Cocrmentioning

confidence: 99%

Section: Cocrmentioning

confidence: 99%

Section: Future Research Avenuementioning

confidence: 99%

Section: Future Research Avenuementioning

confidence: 99%

See 3 more Smart Citations

Review—Electropolishing of Additive Manufactured Metal Parts

Chaghazardi

Wüthrich

2022

J. Electrochem. Soc.

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On the Post‐Processing of Complex Additive Manufactured Metallic Parts: A Review

Pourrahimi,

Hof

2024

Adv Eng Mater

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Additive manufacturing (AM) is gaining more attention due to its capability to produce customized and complex geometries. However, one significant drawback of AM is the rough surface finish of the as‐built parts, necessitating post‐processing for achieving the desired surface quality that meets application requirements. Post‐processing of complex geometries, such as parts with internal holes, lattice structures, and free‐form surfaces, poses unique challenges compared to other components. This review classifies various post‐processing methods employed for complex AM parts, presenting the experimental conditions for each treatment alongside the resulting improvement in surface roughness as a success criterion. The post‐processing methods are categorized into four groups: electrochemical polishing (ECP), chemical polishing (CP), mechanical polishing, and hybrid methods. Notably, mechanical methods exhibit the highest roughness improvement at 69.9%, followed by ECP (59.9%), hybrid methods (47.4%), and CP (49.5%). Nevertheless, mechanical post‐processing techniques are less frequently utilized for lattice parts, making chemical or electrochemical methods more promising alternatives. In summary, all four categories of post‐processing methods can improve the internal surfaces quality of AM holes. While mechanical methods offer the most substantial roughness improvement overall, chemical and electrochemical methods show particular potential for addressing the challenges associated with complex geometries.This article is protected by copyright. All rights reserved.

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In‐depth investigation and industry plan for enhancing surface finishing of 3D printed polymer composite components: A critical review

Karimi,

Bozorgnia Tabary,

Fayazfar

2024

J of Applied Polymer Sci

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Additive manufacturing (AM) is pivotal in modern manufacturing, allowing diverse materials to create functional parts. Polymer composites, with superior properties like enhanced mechanics and conductivity, are highly regarded. Fused deposition modeling (FDM) is a favored, cost‐effective AM technique. Despite popularity, FDM struggles with poor surface quality, impacting final part properties. This challenge affects composite part performance, prompting a need for surface quality enhancements in AM processes, like FDM. The review explores essential post‐treatments required to optimize composite parts for various applications. It examines surface finishing techniques for FDM 3D printed polymeric composites, categorizing them into chemical, thermal, and physical methods. Recent research is extensively analyzed, offering a comprehensive guide for academia and industry. The review covers diverse aspects, including properties, surface morphology, electrical conductivity, and mechanical properties pre‐ and post‐finishing methods. Additionally, it summarizes leading companies worldwide providing surface finishing services for 3D printed polymer parts. Discussions on future trends, challenges, and research gaps in this field are included, emphasizing its significance in refining surface finishing methods for FDM 3D‐printed polymeric composites and encouraging broader industrial adoption of AM. This overview serves as a crucial roadmap for engineers, scientists, customers, and companies interested in surface finishing services.

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Electrochemical-Based Surface Enhancement of Additively Manufactured Ti-6Al-4V Complex Structures

Cited by 12 publications

References 32 publications

Review—Electropolishing of Additive Manufactured Metal Parts

Review—Electropolishing of Additive Manufactured Metal Parts

On the Post‐Processing of Complex Additive Manufactured Metallic Parts: A Review

In‐depth investigation and industry plan for enhancing surface finishing of 3D printed polymer composite components: A critical review

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