Skip to main content

Advertisement

SpringerLink
Log in

Study of the surface roughness of a remanufactured bimetallic AISI 1045 and 316L SS part obtained by hybrid manufacturing (DED/HSM)

  • Application
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Directed energy deposition (DED) is an additive manufacturing process that produces remanufacturers and repairs metal parts and its unique characteristics enable the combination of materials with different properties and surface functionalization. However, DED alone does not always produce surfaces and dimensional quality suitable for most intended applications, thus requiring post-processing steps. Research on post-processing materials obtained by metal additive manufacturing has focused on non-conventional processes, primarily over flat surfaces. Little emphasis has been placed on surface characteristics, mainly when traditional operations are conducted on more intricate geometries. DED and machining can be combined in the same equipment, in what is called hybrid manufacturing (HM). This research work performs an example of remanufacturing using an HM process. An injection mold part, originally in AISI 1045, was remanufactured with AISI 316L stainless steel with the use of laser-based directed energy deposition (DED-LB) and high-speed machining (HSM) towards improving surface finishing and dimensional accuracy. The parameters and strategy employed by DED-LB obtained a material with no significant porosity, cracks, or microstructure defects. The stainless steel improved the corrosion resistance of the component; the resulting microstructure was similar to those obtained in similar works and hardness was slightly higher, enhancing the wear resistance. An analysis of surface roughness using Sa revealed different roughness values for the side and top areas with a strong dependency on both trajectory and semi-melted particles. The HSM process reduced the Sa value by approximately 90% with relatively short times in comparison to other surface finishing processes. The remanufacturing of components by DED-LB deposition of stainless steel onto carbon steels has opened a wide range of new applications, especially for complex 3D surfaces belonging to high-value components.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

Availability of data and materials

The data used in this research are properly cited in the article.

References

  1. Ingarao G (2017) Manufacturing strategies for efficiency in energy and resources use: the role of metal shaping processes. J Clean Prod 142:2872–2886. https://doi.org/10.1016/j.jclepro.2016.10.182

    Article  Google Scholar 

  2. Saboori A, Aversa A, Marchese G et al (2019) Application of directed energy deposition-based additive manufacturing in repair. Appl Sci. https://doi.org/10.3390/app9163316

    Article  Google Scholar 

  3. Leino M, Pekkarinen J, Soukka R (2016) The role of laser additive manufacturing methods of metals in repair, refurbishment and remanufacturing - enabling circular economy. Phys Procedia 83:752–760. https://doi.org/10.1016/j.phpro.2016.08.077

    Article  Google Scholar 

  4. Shrivastava A, Mukherjee S, Chakraborty SS (2021) Addressing the challenges in remanufacturing by laser-based material deposition techniques. Opt Laser Technol 144:107404. https://doi.org/10.1016/j.optlastec.2021.107404

    Article  Google Scholar 

  5. Parkinson HJ, Thompson G (2003) Analysis and taxonomy of remanufacturing industry practice. Proc Inst Mech Eng Part E J Process Mech Eng 217:243–256. https://doi.org/10.1243/095440803322328890

    Article  Google Scholar 

  6. King AM, Burgess SC, Ijomah W, McMahon CA (2006) Reducing waste: repair, recondition, remanufacture or recycle? Sustain Dev 14:257–267. https://doi.org/10.1002/sd.271

    Article  Google Scholar 

  7. Bashkite V, Karaulova T, Starodubtseva O (2014) Framework for innovation-oriented product end-of-life strategies development. Procedia Eng 69:526–535. https://doi.org/10.1016/j.proeng.2014.03.022

    Article  Google Scholar 

  8. Wahab DA, Blanco-Davis E, Ariffin AK, Wang J (2018) A review on the applicability of remanufacturing in extending the life cycle of marine or offshore components and structures. Ocean Eng 169:125–133. https://doi.org/10.1016/j.oceaneng.2018.08.046

    Article  Google Scholar 

  9. Kerr W, Ryan C (2001) Eco-efficiency gains from remanufacturing: a case study of photocopier remanufacturing at Fuji Xerox Australia. J Clean Prod 9:75–81. https://doi.org/10.1016/S0959-6526(00)00032-9

    Article  Google Scholar 

  10. Jones J, McNutt P, Tosi R et al (2012) Remanufacture of turbine blades by laser cladding, machining and in-process scanning in a single machine. 23rd Annu Int Solid Free Fabr Symp - An Addit Manuf Conf SFF 2012 821–827

  11. Fegade V, Shrivatsava RL, Kale AV (2015) Design for remanufacturing: methods and their approaches. Mater Today Proc 2:1849–1858. https://doi.org/10.1016/j.matpr.2015.07.130

    Article  Google Scholar 

  12. Hatcher GD, Ijomah WL, Windmill JFC (2011) Design for remanufacture: a literature review and future research needs. J Clean Prod 19:2004–2014. https://doi.org/10.1016/j.jclepro.2011.06.019

    Article  Google Scholar 

  13. Lee CM, Woo WS, Roh YH (2017) Remanufacturing: trends and issues. Int J Precis Eng Manuf - Green Technol 4:113–125. https://doi.org/10.1007/s40684-017-0015-0

    Article  Google Scholar 

  14. Nasr NZ (2007) Remanufacturing from technology to applications. China Surf Eng

  15. Vundru C, Singh R, Yan W, Karagadde S (2020) The effect of martensitic transformation on the evolution of residual stresses and identification of the critical linear mass density in direct laser metal deposition-based repair. J Manuf Sci Eng Trans ASME. https://doi.org/10.1115/1.4046828

    Article  Google Scholar 

  16. Díaz E, Amado JM, Montero J et al (2012) Comparative Study of Co-based Alloys in Repairing Low Cr-Mo steel Components by Laser Cladding. Phys Procedia 39:368–375. https://doi.org/10.1016/j.phpro.2012.10.050

    Article  Google Scholar 

  17. Chmielewski T, Golański D (2015) The role of welding in the remanufacturing process. Weld Int 29:861–864. https://doi.org/10.1080/09507116.2014.937604

    Article  Google Scholar 

  18. Chen CR, Wang Y, Ou HA, Gindy N (2012) Remanufacture of Die Casting Dies. Appl Mech Mater 1–4. https://doi.org/10.4028/www.scientific.net/AMM.121-126.3482

  19. Astarita A, Coticelli F, Prisco U (2016) Repairing of an engine block through the cold gas dynamic spray technology. Mater Res 19:1226–1231. https://doi.org/10.1590/1980-5373-MR-2016-0109

    Article  Google Scholar 

  20. Wei Z, Yong-ming G, Yong-xiong C (2011) Applications and Future Development of Thermal Spraying Technologies for Remanufacturing Engineering. China Surf Eng

  21. Huang R, Riddle M, Graziano D et al (2016) Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components. J Clean Prod 135:1559–1570. https://doi.org/10.1016/j.jclepro.2015.04.109

    Article  Google Scholar 

  22. Kumar V, Shirodkar PS, Camelio JA, Sutherland JW (2007) Value flow characterization during product lifecycle to assist in recovery decisions. Int J Prod Res 45:4555–4572. https://doi.org/10.1080/00207540701474633

    Article  MATH  Google Scholar 

  23. Ramani K, Ramanujan D, Bernstein WZ et al (2010) Integrated sustainable life cycle design: a review. J Mech Des Trans ASME 132:0910041–09100415. https://doi.org/10.1115/1.4002308

    Article  Google Scholar 

  24. Wilson JM, Piya C, Shin YC et al (2014) Remanufacturing of turbine blades by laser direct deposition with its energy and environmental impact analysis. J Clean Prod 80:170–178. https://doi.org/10.1016/j.jclepro.2014.05.084

    Article  Google Scholar 

  25. Zhang HC, Liu S, Lu H, Zhang Y, Hu Y (2002) Remanufacturing and remaining useful life assessment. Handb Manuf Eng Technol 103:239–248. https://doi.org/10.1007/978-1-4471-4670-4_112

  26. Mahamood RM (2018) Areas of application of laser metal deposition process–part repair and remanufacturing. In: Laser Metal Deposition Process of Metals, Alloys, and Composite Materials 143–164. https://doi.org/10.1007/978-3-319-64985-6_7

  27. Ruiz-Salas E, González-Barrio H, Calleja-Ochoa A et al (2018) Turbo engine components repair methodology by laser material deposition. Dyna 93:643–649. https://doi.org/10.6036/8838

    Article  Google Scholar 

  28. Alfred I, Nicolaus M, Hermsdorf J et al (2018) Advanced high pressure turbine blade repair technologies. Procedia CIRP 74:214–217. https://doi.org/10.1016/j.procir.2018.08.097

    Article  Google Scholar 

  29. Rottwinkel B, Nölke C, Kaierle S, Wesling V (2014) Crack repair of single crystal turbine blades using laser cladding technology. Procedia CIRP 22:263–267. https://doi.org/10.1016/j.procir.2014.06.151

    Article  Google Scholar 

  30. Kaierle S, Overmeyer L, Alfred I et al (2017) Single-crystal turbine blade tip repair by laser cladding and remelting. CIRP J Manuf Sci Technol 19:196–199. https://doi.org/10.1016/j.cirpj.2017.04.001

    Article  Google Scholar 

  31. Liu R, Wang Z, Sparks T et al (2017) Aerospace applications of laser additive manufacturing. In: Laser Additive Manufacturing: Materials, Design, Technologies, and Applications 351–371

  32. Portolés L, Jordá O, Jordá L et al (2016) A qualification procedure to manufacture and repair aerospace parts with electron beam melting. J Manuf Syst 41:65–75. https://doi.org/10.1016/j.jmsy.2016.07.002

    Article  Google Scholar 

  33. Dey NK (2014) laser deposition of Ti-6Al-4V for aerospace repair application. Missouri University of Science and Technology

  34. Liu Q, Janardhana M, Hinton B et al (2011) Laser cladding as a potential repair technology for damaged aircraft components. Int J Struct Integr 2:314–331. https://doi.org/10.1108/17579861111162914

    Article  Google Scholar 

  35. Bennett J, Garcia D, Kendrick M et al (2019) Repairing automotive dies with directed energy deposition: industrial application and life cycle analysis. J Manuf Sci Eng Trans ASME 141:1–9. https://doi.org/10.1115/1.4042078

    Article  Google Scholar 

  36. Kattire P, Paul S, Singh R, Yan W (2015) Experimental characterization of laser cladding of CPM 9V on H13 tool steel for die repair applications. J Manuf Process 20:492–499. https://doi.org/10.1016/j.jmapro.2015.06.018

    Article  Google Scholar 

  37. Chen C, Wang Y, Ou H et al (2014) A review on remanufacture of dies and moulds. J Clean Prod 64:13–23. https://doi.org/10.1016/j.jclepro.2013.09.014

    Article  Google Scholar 

  38. Oh WJ, Lee WJ, Kim MS et al (2019) Repairing additive-manufactured 316L stainless steel using direct energy deposition. Opt Laser Technol 117:6–17. https://doi.org/10.1016/j.optlastec.2019.04.012

    Article  Google Scholar 

  39. Yu JH, Choi YS, Shim DS, Park SH (2018) Repairing casting part using laser assisted additive metal-layer deposition and its mechanical properties. Opt Laser Technol 106:87–93. https://doi.org/10.1016/j.optlastec.2018.04.007

    Article  Google Scholar 

  40. Lewis SR, Lewis R, Fletcher DI (2015) Assessment of laser cladding as an option for repairing/enhancing rails. Wear 330–331:581–591. https://doi.org/10.1016/j.wear.2015.02.027

    Article  Google Scholar 

  41. Barragan GA, Rojas D, Grass JS, Coelho RT (2021) Observations on laser additive manufacturing (lam) in terms of directed energy deposition (ded) with metal powder feedstock. Lasers Eng 50:117–141

    Google Scholar 

  42. Wang X, He X, Wang T, Li Y (2019) Internal pores in DED Ti-6.5Al-2Zr-Mo-V alloy and their influence on crack initiation and fatigue life in the mid-life regime. Addit Manuf 28:373–393. https://doi.org/10.1016/j.addma.2019.05.007

    Article  Google Scholar 

  43. Liu F, Lin X, Shi J et al (2019) Effect of microstructure on the Charpy impact properties of directed energy deposition 300M steel. Addit Manuf 29:100795. https://doi.org/10.1016/j.addma.2019.100795

    Article  Google Scholar 

  44. Shamsaei N, Yadollahi A, Bian L, Thompson SM (2015) An overview of direct laser deposition for additive manufacturing; Part II: Mechanical behavior, process parameter optimization and control. Addit Manuf 8:12–35. https://doi.org/10.1016/j.addma.2015.07.002

    Article  Google Scholar 

  45. Praniewicz M, Kurfess T, Saldana C (2018) Adaptive geometry transformation and repair for hybrid manufacturing 26:228–236. https://doi.org/10.1016/j.promfg.2018.07.031

    Article  Google Scholar 

  46. Thompson MK, Moroni G, Vaneker T et al (2016) Design for additive manufacturing: trends, opportunities, considerations, and constraints. CIRP Ann - Manuf Technol 65:737–760. https://doi.org/10.1016/j.cirp.2016.05.004

    Article  Google Scholar 

  47. Zhu Z, Dhokia VG, Nassehi A, Newman ST (2013) A review of hybrid manufacturing processes - state of the art and future perspectives. Int J Comput Integr Manuf 26:596–615. https://doi.org/10.1080/0951192X.2012.749530

    Article  Google Scholar 

  48. Lorenz KA, Jones JB, Wimpenny DI, Jackson MR (2020) A review of hybrid manufacturing. Proc - 26th Annu Int Solid Free Fabr Symp - An Addit Manuf Conf SFF 96–108

  49. Lauwers B, Klocke F, Klink A et al (2014) Hybrid processes in manufacturing. CIRP Ann - Manuf Technol 63:561–583. https://doi.org/10.1016/j.cirp.2014.05.003

    Article  Google Scholar 

  50. Flynn JM, Shokrani A, Newman ST, Dhokia V (2016) Hybrid additive and subtractive machine tools - research and industrial developments. Int J Mach Tools Manuf 101:79–101. https://doi.org/10.1016/j.ijmachtools.2015.11.007

    Article  Google Scholar 

  51. Le VT, Paris H (2018) A life cycle assessment-based approach for evaluating the influence of total build height and batch size on the environmental performance of electron beam melting. Int J Adv Manuf Technol 98:275–288. https://doi.org/10.1007/s00170-018-2264-7

    Article  Google Scholar 

  52. Ostolaza M, Arrizubieta JI, Lamikiz A, Cortina M (2021) Functionally graded AISI 316L and AISI H13 manufactured by L-DED for die and mould applications. Appl Sci 11:1–11. https://doi.org/10.3390/app11020771

    Article  Google Scholar 

  53. Barragan GA, Mariani F, Coelho RT (2021) Application of 316L stainless steel coating by directed energy deposition process. IOP Conf Ser Mater Sci Eng 1154:012014. https://doi.org/10.1088/1757-899x/1154/1/012014

    Article  Google Scholar 

  54. Evangeline A, Sathiya P (2021) Dissimilar cladding of Ni–Cr–Mo superalloy over 316L austenitic stainless steel: morphologies and mechanical properties. Met Mater Int 27:1155–1172. https://doi.org/10.1007/s12540-019-00440-x

    Article  Google Scholar 

  55. Yamaguchi H, Fergani O, Wu PY (2017) Modification using magnetic field-assisted finishing of the surface roughness and residual stress of additively manufactured components. CIRP Ann - Manuf Technol 66:305–308. https://doi.org/10.1016/j.cirp.2017.04.084

    Article  Google Scholar 

  56. Tyagi P, Goulet T, Riso C et al (2019) Reducing the roughness of internal surface of an additive manufacturing produced 316 steel component by chempolishing and electropolishing. Addit Manuf 25:32–38. https://doi.org/10.1016/j.addma.2018.11.001

    Article  Google Scholar 

  57. Kaynak Y, Kitay O (2018) Porosity, surface quality, microhardness and microstructure of selective laser melted 316l stainless steel resulting from finish machining. J Manuf Mater Process. https://doi.org/10.3390/jmmp2020036

    Article  Google Scholar 

  58. Guo P, Zou B, Huang C, Gao H (2017) Study on microstructure, mechanical properties and machinability of efficiently additive manufactured AISI 316L stainless steel by high-power direct laser deposition. J Mater Process Technol 240:12–22. https://doi.org/10.1016/j.jmatprotec.2016.09.005

    Article  Google Scholar 

  59. Yang Y, Gong Y, Qu S et al (2020) Densification, mechanical behaviors, and machining characteristics of 316L stainless steel in hybrid additive/subtractive manufacturing. Int J Adv Manuf Technol 107:177–189. https://doi.org/10.1007/s00170-020-05033-2

    Article  Google Scholar 

  60. Gong Y, Li P (2019) Analysis of tool wear performance and surface quality in post milling of additive manufactured 316L stainless steel. J Mech Sci Technol 33:2387–2395. https://doi.org/10.1007/s12206-019-0237-x

    Article  Google Scholar 

  61. Yang Y, Gong Y, Li C et al (2021) Mechanical performance of 316 L stainless steel by hybrid directed energy deposition and thermal milling process. J Mater Process Technol 291:117023. https://doi.org/10.1016/j.jmatprotec.2020.117023

    Article  Google Scholar 

  62. ASM International Handbook Committee (1990) ASTM Handbook , Volume 01 - Properties and Selection : Irons , Steels , and High-Performance Alloys. ASM International

  63. Ahsan MRU, Tanvir ANM, Ross T et al (2020) Fabrication of bimetallic additively manufactured structure (BAMS) of low carbon steel and 316L austenitic stainless steel with wire + arc additive manufacturing. Rapid Prototyp J 26:519–530. https://doi.org/10.1108/RPJ-09-2018-0235

    Article  Google Scholar 

  64. ROMI Centro de Usinagem Vertical ROMI DCM 620–5X H. In: 2022. http://www.romi.com/produtos/romi-hybrid/. Accessed 2 Feb 2022

  65. Gong Y, Yang Y, Qu S et al (2019) Laser energy density dependence of performance in additive/subtractive hybrid manufacturing of 316L stainless steel. Int J Adv Manuf Technol 105:1585–1596. https://doi.org/10.1007/s00170-019-04372-z

    Article  Google Scholar 

  66. Souza AM, Ferreira R, Barragán G et al (2021) Effects of laser polishing on surface characteristics and wettability of directed energy-deposited 316L stainless steel. J Mater Eng Perform 30:6752–6765. https://doi.org/10.1007/s11665-021-05991-y

    Article  Google Scholar 

  67. De Lima MSF, Sankaré S (2014) Microstructure and mechanical behavior of laser additive manufactured AISI 316 stainless steel stringers. Mater Des 55:526–532. https://doi.org/10.1016/j.matdes.2013.10.016

    Article  Google Scholar 

  68. Sun GF, Shen XT, Wang ZD et al (2019) Laser metal deposition as repair technology for 316L stainless steel: influence of feeding powder compositions on microstructure and mechanical properties. Opt Laser Technol 109:71–83. https://doi.org/10.1016/j.optlastec.2018.07.051

    Article  Google Scholar 

  69. Elmer JW, Allen SM, Eagar TW (1989) Microstructural development during solidification of stainless steel alloys. Metall Trans A 20:2117–2131. https://doi.org/10.1007/BF02650298

    Article  Google Scholar 

  70. Lanzutti A, Marin E, Tamura K et al (2020) High temperature study of the evolution of the tribolayer in additively manufactured AISI 316L steel. Addit Manuf 34:101258. https://doi.org/10.1016/j.addma.2020.101258

    Article  Google Scholar 

  71. Le VT, Paris H, Mandil G (2018) The development of a strategy for direct part reuse using additive and subtractive manufacturing technologies. Addit Manuf 22:687–699. https://doi.org/10.1016/j.addma.2018.06.026

    Article  Google Scholar 

  72. Vishnuja U, Bhaskar GB (2018) Study on AISI1045 material for various applications: an over view. Int J Eng Manuf Sci 8:125–144

    Google Scholar 

  73. Käsemodel RB, de Souza AF, Voigt R et al (2020) CAD/CAM interfaced algorithm reduces cutting force, roughness, and machining time in free-form milling. Int J Adv Manuf Technol 107:1883–1900. https://doi.org/10.1007/s00170-020-05143-x

    Article  Google Scholar 

  74. Quintana G, Garcia-Romeu ML, Ciurana J (2011) Surface roughness monitoring application based on artificial neural networks for ball-end milling operations. J Intell Manuf 22:607–617. https://doi.org/10.1007/s10845-009-0323-5

    Article  Google Scholar 

  75. Schroepfer D, Treutler K, Boerner A et al (2021) Surface finishing of hard-to-machine cladding alloys for highly stressed components. Int J Adv Manuf Technol 114:1427–1442. https://doi.org/10.1007/s00170-021-06815-y

    Article  Google Scholar 

  76. Batista MF, Rodrigues AR, Coelho RT (2017) Modelling and characterisation of roughness of moulds produced by high-speed machining with ball-nose end mill. Proc Inst Mech Eng Part B J Eng Manuf 231:933–944. https://doi.org/10.1177/0954405415584898

    Article  Google Scholar 

Download references

Funding

This study was partially financed by the São Paulo Research Foundation (FAPESP) grants 2016/11309–0 and 2019/26362–2, Coordenação de Aperfeiçoamento de Pessoal de Nível Superior, Brasil (CAPES), Finance Code 001, and Universidad Pontificia Bolivariana CDG-19 agreement.

Author information

Authors and Affiliations

  1. Grupo de Investigación en Ingeniería Aeroespacial, Universidad Pontificia Bolivariana, Circular 1 # 70 -01, Medellín, Colombia

    German Alberto Barragan De Los Rios

  2. Department of Control and Industrial Processes, Federal Institute of Pernambuco, Av. Prof. Luís Freire, 500 - Cidade Universitaria, Recife/Pernambuco, Brazil

    Rodrigo Ferreira

  3. Laboratory for Advanced Process and Sustainability (LAPRAS), São Carlos School of Engineering, Av. São Carlense, 400, São Carlos/São Paulo, CEP, 13566-590, Brazil

    Fabio Edson Mariani, Eraldo Jannone da Silva & Reginaldo Teixeira Coelho

Authors
  1. German Alberto Barragan De Los Rios
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Rodrigo Ferreira
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Fabio Edson Mariani
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Eraldo Jannone da Silva
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Reginaldo Teixeira Coelho
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All related authors contributed to the conceptualization, data curation, investigation, methodology, writing–original draft, writing–review, and editing of the manuscript.

Corresponding author

Correspondence to German Alberto Barragan De Los Rios.

Ethics declarations

Ethics approval

The authors understand and have approved their ethical responsibilities.

Consent to participate

The authors consented to participate.

Consent to publish

The authors consent to transfer copyright of the article to be published.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Barragan De Los Rios, G.A., Ferreira, R., Mariani, F.E. et al. Study of the surface roughness of a remanufactured bimetallic AISI 1045 and 316L SS part obtained by hybrid manufacturing (DED/HSM). Int J Adv Manuf Technol 124, 3185–3199 (2023). https://doi.org/10.1007/s00170-022-09179-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-09179-z

Keywords

Search

Navigation