Optimization of Process Parameters for Abrasive Water Jet Internal Channel Surfaces

Abstract

To address the issues of surface roughness and spheroidization in the internal channels of additively manufactured high-temperature alloys with a large aspect ratio, a study on abrasive water jet polishing using synthetic silicon carbide was conducted. A full factorial experimental design was employed to explore the effects of three sets of process parameters: polishing pressure, abrasive concentration, and polishing time, on the quality of the channel surfaces. Additionally, the finishing effects of two different abrasive grain sizes under these parameters were compared. A generalized factorial regression model was constructed, which indicated that the significant factors affecting the surface quality of the channels were, in order, pressure, concentration, and time. An analysis of the process parameters and measurement data was carried out, determining the optimal polishing parameters for the internal channels. The surface characteristics of the runners were analyzed using surface morphology. The experiments clearly enhanced the finishing and surface quality of internal runners in additively manufactured high-temperature alloys, effectively solving the problem of spheroidization that occurs during the printing process of additive metal components.