Abstract
Post-processing of additively manufactured (AM) aluminium alloy parts via laser polishing (LP) is particularly challenging due to the materials’ high thermal conductivity, diffusivity, and reflectivity. Here, a novel multi-step laser polishing strategy, by combining laser ablation and smoothing steps, is developed that effectively reduces the surface roughness of AM AlSi10Mg parts. The minimum average roughness (Sa) and 10-point height (S10z) are achieved as 1.81 µm and 23.7 µm, representing maximum reductions of 94.1% and 89.8%, respectively, from the as-built AM surfaces (initial Sa 8–28 µm). A strong relationship has been observed between the initial surface roughness and the achievable roughness reduction. Regarding the other surface integrity factors, sub-surface microhardness (between 10–40 µm) after LP increases up to 182 HV0.01, compared to the bulk hardness (105 HV0.01) measured ~60 µm below the surface. Clear evidence of material’s flow within the surface asperities during the LP steps is observed from the cross-sectional microstructures. Further study will involve in-depth analysis of materials’ compositions within the LP-processed layers.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Hofele, M., et al.: Process parameter dependencies of continuous and pulsed laser modes on surface polishing of additive manufactured aluminium AlSi10Mg parts. Materwiss. Werksttech. 52, 409–432 (2021). https://doi.org/10.1002/mawe.202000335
Whitehouse, D.J.: Surfaces and their Measurement. Kogan Page Science, London (2004)
Brandão, A.D., et al.: Fatigue properties of additively manufactured AlSi10Mg-surface treatment effect. Procedia Struct. Integr. 7, 58–66 (2017). https://doi.org/10.1016/j.prostr.2017.11.061
du Plessis, A., Beretta, S.: Killer notches: the effect of as-built surface roughness on fatigue failure in AlSi10Mg produced by laser powder bed fusion. Addit. Manuf. 35, 101424 (2020). https://doi.org/10.1016/j.addma.2020.101424
Calignano, F.: Investigation of the accuracy and roughness in the laser powder bed fusion process. Virtual Phys. Prototyp. 13, 97–104 (2018). https://doi.org/10.1080/17452759.2018.1426368
Fox, J.C., Moylan, S.P., Lane, B.M.: Effect of process parameters on the surface roughness of overhanging structures in laser powder bed fusion additive manufacturing. Procedia CIRP. 45, 131–134 (2016). https://doi.org/10.1016/j.procir.2016.02.347
Thijs, L., Kempen, K., Kruth, J.P., Van Humbeeck, J.: Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder. Acta Mater. 61, 1809–1819 (2013). https://doi.org/10.1016/j.actamat.2012.11.052
Wyatt, H., Elliott, M., Revill, P., Clarke, A.: The effect of engineered surface topography on the tribology of CFR-PEEK for novel hip implant materials. Biotribology. 7, 22–30 (2016). https://doi.org/10.1016/j.biotri.2016.08.001
Xu, W.L., Yue, T.M., Man, H.C., Chan, C.P.: Laser surface melting of aluminium alloy 6013 for improving pitting corrosion fatigue resistance. Surf. Coatings Technol. 200, 5077–5086 (2006). https://doi.org/10.1016/j.surfcoat.2005.05.034
Bhaduri, D., et al.: Laser polishing of 3D printed mesoscale components. Appl. Surf. Sci. 405, 29–46 (2017). https://doi.org/10.1016/j.apsusc.2017.01.211
Renishaw plc.: AlSi10Mg-0403 powder for additive manufacturing, www.renishaw.com/additive (2015)
Materion Microelectronics & Services: Reflectance in Thin Films (2007)
Zhang, D. et al.: Investigation of laser polishing of four selective laser melting alloy samples. Appl. Sci. 10(3), 760 (2020). https://doi.org/10.3390/app10030760
Bhaduri, D., et al.: Pulsed laser polishing of selective laser melted aluminium alloy parts. Appl. Surf. Sci. 558, 149887 (2021). https://doi.org/10.1016/j.apsusc.2021.149887
Zhou, J., et al.: In-situ laser polishing additive manufactured AlSi10Mg: effect of laser polishing strategy on surface morphology. Roughness Microhardness. Mater. (Basel) 14, 1–19 (2021). https://doi.org/10.3390/ma14020393
Hofele, M., et al.: Laser polishing of laser powder bed fusion AlSi10Mg parts—influence of initial surface roughness on achievable surface quality. Mater. Sci. Appl. 12, 15–41 (2021). https://doi.org/10.4236/msa.2021.121002
Petkov, P.V., Penchev, P., Lacan, F., Bigot, S.: Finishing of Titanium ALM parts by Laser Ablation. In: WCMNM 2018 World Congress on Micro and Nano Manufacturing, pp. 111–114. Research Publishing Services, Singapore (2018). https://doi.org/10.3850/978-981-11-2728-1_85
Danzl, R., Helmli, F., Scherer, S.: Focus variation - a robust technology for high resolution optical 3D surface metrology. Stroj. Vestnik/J. Mech. Eng. 57, 245–256 (2011). https://doi.org/10.5545/sv-jme.2010.175
Acknowledgements
This research is supported by the EPSRC Doctoral Training Programme. Thanks are due to the Cardiff University’s technical staff team during sample preparation. Special thanks are for Dr P. Penchev of the University of Birmingham and Prof R. Leach of the University of Nottingham for their valuable advice during the project. Special thanks must go to Dr F. Lacan for manufacturing the samples used throughout.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2023 The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.
About this paper
Cite this paper
Mason, B., Ryan, M., Setchi, R., Kundu, A., Ayre, W.N., Bhaduri, D. (2023). Development of a Novel Laser Polishing Strategy for Additively Manufactured AlSi10Mg Alloy Parts. In: Scholz, S.G., Howlett, R.J., Setchi, R. (eds) Sustainable Design and Manufacturing. SDM 2022. Smart Innovation, Systems and Technologies, vol 338. Springer, Singapore. https://doi.org/10.1007/978-981-19-9205-6_26
Download citation
DOI: https://doi.org/10.1007/978-981-19-9205-6_26
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-19-9204-9
Online ISBN: 978-981-19-9205-6
eBook Packages: EngineeringEngineering (R0)