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Surface finishing of additively manufactured IN718 lattices by electrochemical machining

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Abstract

Metal additive manufacturing offers design freedom, but high surface roughness can limit key properties such as fatigue and pressure drop. Machining all over is a common strategy to mitigate surface roughness, which unfortunately becomes technically and economically prohibitive in the case of significant geometric complexity, e.g., an internal lattice structure. In this paper, a strategy for finishing the surfaces of lattices using the commercial electrochemical machining (ECM) process COOLPULSE is proposed and demonstrated. Inconel 718 lattice coupons and complementing cathode tooling were designed and manufactured via laser powder bed fusion (LPBF). The tooling featured prongs to reach into the core of the lattice coupon in order to establish proximity between cathode and lattice surface (workpiece) as well as ports to allow electrolyte circulation in and around the lattice coupon. Both features extended the electrochemically active region into the core of the workpiece. Inspection of the processed lattice specimens revealed that a significant amount of material was removed from internal surfaces with accompanying improvement in roughness. Depth profiling indicated that the improvement of lattice surface state extended well into the core of the specimen without diminishment, in contrast to an external-only blasting process.

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Acknowledgments

The authors thank Srinivasa Venkatesha, Vitali Weber, Andreas Steiber, and Fabio Wosniak of Extrude Hone for assistance with design, simulation, visualization, and processing; Luke Moran, Ray Amin, and Jay Tomko of Extrude Hone, Jesse Boyer of Pratt & Whitney, Jackie Garofano of Raytheon Technologies, and Anthony Ventura of RTRC for helpful discussion; and Justina Leung of RTRC for assistance with measurements.

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  1. Kerisha Williams

    Present address: School of Materials Science and Engineering, Georgia Tech, 771 Ferst Drive, J. Erskine Love Building, Atlanta, GA, 30332-0245, USA

Authors and Affiliations

  1. Raytheon Technologies Research Center, 411 Silver Lane, East Hartford, CT, 06108, USA

    Matthew E. Lynch & Kerisha Williams

  2. Extrude Hone GmbH, Bgm.-Merk-Str. 1, 87752, Holzgünz, Germany

    Mariana Cabrera & Tommaso Beccuti

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  1. Matthew E. Lynch
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Correspondence to Matthew E. Lynch.

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Lynch, M.E., Williams, K., Cabrera, M. et al. Surface finishing of additively manufactured IN718 lattices by electrochemical machining. Int J Adv Manuf Technol 113, 967–984 (2021). https://doi.org/10.1007/s00170-020-05699-8

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