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Surface Characteristics of Ti–6Al–4V Alloy Based on the Process Parameter and Abrasive Process in the Laser Powder Bed Fusion

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Abstract

The surface quality of three-dimensional products manufactured via laser powder bed fusion (L-PBF) depends on solidification conditions, the staircase effect caused by layer-by-layer build-up processes, and the shape and size of un-melted particles. Although the surface quality can be slightly improved by optimizing process parameters such as layer thickness, laser power, hatch spacing and scan speed, the effect is quite limited, and thus additional post-treatment processes are required for dramatic improvement. In the paper, the effects of layer thickness (30, 60 µm) and build angle (0°, 15°, 30°, 45°, 60°, 75°, 90°) on the surface roughness of the Ti–6Al–4V alloy parts manufactured by L-PBF process were analyzed. In addition, in order to investigate the effect of blasting conditions on the surface roughness, the specimens were post-treated by various sizes of abrasives (#60, #80, #100, #120, #150), blasting angle (45°, 90°), and pressures (0.3, 0.4, 0.5 MPa), and the surface roughness of each specimen was measured and compared. The results indicate that the higher is the building angle and thinner is the layer thickness, the better is the surface quality; however, the difference tends to decrease via sandblasting, and the effect depends on the process conditions. Sandblasting process improved the surface roughness up to 62% and 71% compared as-built conditions for the layer thickness 30 µm and 60 µm for each. As a result, the surface roughness of minimum 5.0 µm and 3.8 µm for the layer thickness 60 µm and 30 µm was achieved in the case of building angle 90°.

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Acknowledgements

This work was supported by Fundamental Research Program of the Korea Institute of Material Science (PNK8670, KIMS).

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Authors and Affiliations

  1. Department of Materials Processing, Materials Digital Platform Division, Korea Institute of Materials Science, Changwon, 51508, Republic of Korea

    Won Yeong Kim, Eun Yoo Yoon & Sangwoo Kim

  2. School of Mechanical Engineering, Pusan National University, Busan, 46241, Republic of Korea

    Ji Hoon Kim

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  1. Won Yeong Kim
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Correspondence to Sangwoo Kim.

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Kim, W.Y., Yoon, E.Y., Kim, J.H. et al. Surface Characteristics of Ti–6Al–4V Alloy Based on the Process Parameter and Abrasive Process in the Laser Powder Bed Fusion. Met. Mater. Int. 29, 2345–2357 (2023). https://doi.org/10.1007/s12540-022-01378-3

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