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Effects of post-processing operations on directed energy deposited 316 L stainless steel surfaces

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Abstract

Directed energy deposition (DED) processes apply both material feedstock and energy for a layer-by-layer deposition, resulting in the formation of metallic parts. While DED excels in coatings, functionally graded materials, and repair, additional surface finishing is frequently needed in order to meet project requirements. This is usually due to low dimensional accuracy and poor surface quality. Chemopolishing, electropolishing, and abrasive processes (e.g., magnetic field-assisted finishing (MAF)) are fine-finishing operations that have been used for post-processing similar parts. Although most of these processes require their own specific processing equipment, MAF can be adapted to a machining center used for milling and grinding. This study involves a machining center and describes the investigation of process chains employing milling, grinding, and MAF for post-processing 316 L stainless steel parts manufactured via DED. Parameters considered encompass shape deviation, roughness, microstructure, residual stress, material removal rate, processing time, cutting forces, and specific energy. Results show the post-process chain corrects surface errors without microstructure or hardness changes. Residual stress varies: milling leads to tensile stress, grinding leads to compressive stress, and MAF has minimal impact. Performing milling and grinding operations between DED and MAF minimizes polishing time. Furthermore, grinding reduces material removal in MAF, thereby decreasing the time required for polishing and overall specific energy consumption. This study also showed the feasibility of post-processing—from cutting to fine finishing—of DED parts using a machining center with one-time chucking. This concept will help save overall production time and improve part accuracy during post-AM processing.

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Acknowledgements

The authors would like to thank the following companies: Blaser Swisslube do Brasil Ltda, Materials Institute of Brazil (MIB), and Saint-Gobain Abrasives.

Funding

This work was supported by the Fundaç ao de Amparo á Pesquisa do Estado de São Paulo (FAPESP) (Grant numbers 2016/11309-0 and 2019/10758-4) and the Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq).

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Authors and Affiliations

  1. Department of Mechanical Engineering, São Carlos School of Engineering, University of São Paulo, São Paulo, Brazil

    Adriel Magalhães Souza

  2. Department of Production Engineering, São Carlos School of Engineering, University of São Paulo, São Paulo, Brazil

    Eraldo Jannone da Silva

  3. Department of Mechanical and Aerospace Engineering, University of Florida, Gainesville, FL, USA

    Hitomi Yamaguchi

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  1. Adriel Magalhães Souza
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Souza, A.M., Silva, E.J.d. & Yamaguchi, H. Effects of post-processing operations on directed energy deposited 316 L stainless steel surfaces. Int J Adv Manuf Technol 129, 2087–2109 (2023). https://doi.org/10.1007/s00170-023-12372-3

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