Improving Surface Quality and Fatigue Life of Electron Beam Melted Ti6Al4V by Chemical Machining

Abstract

Due to the high demand for innovative parts from the aerospace, biomedical, and automotive industries, 3D printing of titanium parts is widely researched. Electron beam melting (EBM) is one of the few additive manufacturing techniques that can quickly generate high density components. However, additive manufacturing techniques based on powder beds are characterized by subpar surface finishing, which also results in poor mechanical performances that are not suitable for industrial standards. Thus, surface finishing post processing is generally needed. Since fatigue behavior is strongly affected by surface quality, this work aims to highlight how chemical machining impacts this type of mechanical response. Rotating fatigue beam testing method has been chosen for the experimental campaign since it intrinsically stresses more the sample surfaces, in this way the effect of surface finishing is highlighted.