Electromagnetic performance of Ti6Al4V and AlSi7Mg0.6 waveguides with laser beam melting (LBM) produced and abrasive flow machining (AFM) finished internal surfaces

Moureau, François; Han, Sangil; Segonds, Frédéric; Dupuy, Corinne; Rivette, Mickaël; Turpault, Simon; Mimouna, Mehdi; Salvatore, Ferdinando; Rech, Joël; Peyre, P.

doi:10.1080/09205071.2021.1954554

Cited by 13 publications

(5 citation statements)

References 37 publications

(86 reference statements)

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“…Ke et al (2022) polished the Ti6Al4V with flexible tools, which decreased the surface roughness from the Sa 172.1 nm-6.1 nm. François et al (2021) significantly reduced the surface roughness of LPBF-fabricated waveguide intel surfaces from Ra 9.7 μm-1 μm by abrasive flow polishing. Martin (Bezuidenhout et al, 2020) investigated the effect of chemical polishing with HF- Mechanical, (electro) chemical, and high-energy beam polishing methods all present positive results, but each post-processing method has different pros and cons as well as the applicable situations.…”

Section: Introductionmentioning

confidence: 96%

“…Currently, post-processing methods, such as high-energy beam (e.g., laser and electron beam) polishing (Obeidi et al, 2022;Wang et al, 2023), mechanical polishing (Eyzat et al, 2019;Ke et al, 2022), abrasive flow polishing (Peng et al, 2018;Finazzi et al, 2020;François et al, 2021), sandblasting (Lober et al, 2013), chemical polishing (Balyakin et al, 2018;Bezuidenhout et al, 2020), and electrolytic polishing (Mingear et al, 2019), are used to improve the surface quality of Ti6A14V parts. Wang et al (2023) reduced the surface roughness of column-faced Ti6Al4V by 16 times via electron beam rotary polishing.…”

Section: Introductionmentioning

confidence: 99%

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Effect of post-processing methods on the surface quality of Ti6Al4V fabricated by laser powder bed fusion

Lu¹,

Liu²,

Wei³

et al. 2023

Front. Mater.

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Ti6Al4V is widely used in aerospace and medical applications, where high demands on dimensional accuracy and surface quality require the application of post-processing to achieve optimal performance. However, the surface quality of parts fabricated by LPBF is inferior due to the inherent defects of LPBF. Therefore, it is important to investigate the effect of post-processing on the surface quality of Ti6A14V parts fabricated by LPBF. In this work, the effect of post-processing methods (i.e., sandblasting, electrolytic polishing, chemical polishing, and abrasive flow polishing) on the surface quality of Ti6Al4V fabricated by laser powder bed fusion (LPBF) additive manufacturing was investigated. The changes in surface roughness and morphology of the 45° inclined square and curved pipe Ti6Al4V samples processed with post-processing were observed, and the weight and elemental changes of the parts were also analyzed. The result reveals that sandblasting, electrolytic polishing, chemical polishing, and abrasive flow polishing are all effective in improving the surface quality of Ti6Al4V parts fabricated by LPBF. The effect of sandblasting is mainly caused by sharp-edged grit driven by high-speed airflow, resulting in the lowest surface roughness and the least influence on the weight, but may contaminate the surface with residual brown corundum. Electrolytic polishing and chemical polishing achieve surface quality improvement through different corrosion patterns without changing the surface composition. The surface smoothness of parts processed with chemical polishing is the best, while the weight loss rate of the sample processed with electrolytic polishing is the most at about 7.47%. Abrasive flow polishing presents a remarkable effect on polishing the internal surface of the Ti6Al4V sample by the extrusion scratching, extrusion deformation, and micro-cutting effects of abrasive on the surface. The findings can provide important engineering references for the post-processing of precision Ti6Al4V parts fabricated by LPBF and further promote the engineering applications of Ti6Al4V parts.

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Section: Introductionmentioning

confidence: 96%

Section: Introductionmentioning

confidence: 99%

Effect of post-processing methods on the surface quality of Ti6Al4V fabricated by laser powder bed fusion

Lu¹,

Liu²,

Wei³

et al. 2023

Front. Mater.

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“…This process is referred to as abrasive flow machining (AFM) because abrasive grains (e.g., artificial corundum) are used as particles. AFM can be applied to gears [1], rotor blades [2], tool blades [3], small openings [4,5], internal surfaces of waveguides and elbows [6,7], complex-shaped components, and difficult-to-access surfaces [8,9]. Furthermore, AFM is used for smoothing surfaces, remove burrs [10,11], round edges, and remove the white layer [12], and in 3D printed machine parts [13,14].…”

Section: Introductionmentioning

confidence: 99%

2017A Alloy surface layer after flow burnishing with glass microspheres

Korzynska,

Zarski,

Zeglicki

et al. 2024

Int J Adv Manuf Technol

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This study presents a novel flow processing technique that uses glass microspheres instead of abrasives. The fundamentals of flow machining with glass microspheres, including microsphere flow burnishing (MFB) and the conditions necessary for cutting or plastic deformation of a surface to occur during MFB, are determined. Details on such conditions are lacking, and therefore, this study attempts to define these conditions. To this end, MFB was experimentally confirmed to be a burnishing process, and the effects of MFB and abrasive flow machining (AFM) on 2017A aluminum alloy were compared. Both processes achieved a surface roughness (Sa) of < 0.5 μm, while MFB yielded higher values of surface microhardness and compressive stress. The effects of basic process parameters on the MFB and AFM results (workpiece weight loss and Sa) were compared experimentally and the corresponding mathematical models were established. Utilizing these relationships, MFB parameters can be selected so as to obtain the most favorable surface layer for the expected operating conditions.

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“…To optimize additive technologies for injection mold cooling, further processing of channel surfaces to reduce roughness is imperative, and these facts are discussed by Han et al, Günther et al, and Dumas et al [ 28 , 29 , 30 ]. As conventional types of surface finishing are not suitable to use on internal surfaces, such as cooling channels, on the other hand, Abrasive Flow Machining (AFM) emerges as a suitable method for finishing internal channels produced using additive technologies [ 31 , 32 , 33 , 34 ]. However, AFM technology needs to be deeply researched in the field of injection molding.…”

Section: Introductionmentioning

confidence: 99%

The Impact of Surface Roughness on Conformal Cooling Channels for Injection Molding

Hanzlik,

Vanek,

Pata

et al. 2024

Materials

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Injection molding technology is widely utilized across various industries for its ability to fabricate complex-shaped components with exceptional dimensional accuracy. However, challenges related to injection quality often arise, necessitating innovative approaches for improvement. This study investigates the influence of surface roughness on the efficiency of conformal cooling channels produced using additive manufacturing technologies, specifically Direct Metal Laser Sintering (DMLS) and Atomic Diffusion Additive Manufacturing (ADAM). Through a combination of experimental measurements, including surface roughness analysis, scanning electron microscopy, and cooling system flow analysis, this study elucidates the impact of surface roughness on coolant flow dynamics and pressure distribution within the cooling channels. The results reveal significant differences in surface roughness between DMLS and ADAM technologies, with corresponding effects on coolant flow behavior. Following that fact, this study shows that when cooling channels’ surface roughness is lowered up to 90%, the reduction in coolant media pressure is lowered by 0.033 MPa. Regression models are developed to quantitatively describe the relationship between surface roughness and key parameters, such as coolant pressure, Reynolds number, and flow velocity. Practical implications for the optimization of injection molding cooling systems are discussed, highlighting the importance of informed decision making in technology selection and post-processing techniques. Overall, this research contributes to a deeper understanding of the role of surface roughness in injection molding processes and provides valuable insights for enhancing cooling system efficiency and product quality.

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Electromagnetic performance of Ti6Al4V and AlSi7Mg0.6 waveguides with laser beam melting (LBM) produced and abrasive flow machining (AFM) finished internal surfaces

Cited by 13 publications

References 37 publications

Effect of post-processing methods on the surface quality of Ti6Al4V fabricated by laser powder bed fusion

Effect of post-processing methods on the surface quality of Ti6Al4V fabricated by laser powder bed fusion

2017A Alloy surface layer after flow burnishing with glass microspheres

The Impact of Surface Roughness on Conformal Cooling Channels for Injection Molding

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