Abstract
Electrochemical polishing (ECP) is effective for improving the surface quality of additively manufactured (AM) parts. However, ECP effects of AM parts manufactured from varied materials show significant differences owing to the complexity of phase composition, chemical composition, and specific surface defects. Accordingly, this paper compares the electrochemical polishing (ECP) results and mechanisms of the laser powder bed fusion (LPBF) additive manufacturing (AM) of HR-2 stainless steel (single-phase) and AlSi10Mg (multi-phase). Both kinds of LPBF parts show a significantly smoother surface after the ECP process. Following ECP, the Sa of HR-2 was reduced from 11.50 μm to 1.73 μm, while the Sa of AlSi10Mg was reduced from 14.91 μm to 4.70 μm. Notably, compared with LPBF HR-2, LPBF AlSi10Mg forms a solid viscous layer due to the buildup of polishing products after ECP, thus inhibiting the diffusion and reaction of the ions during the polishing process, resulting in a decrease in the polishing effect. Therefore, an in situ mechanical brushing (ECMP) targeting the product layer is conducted along with the ECP, and the surface roughness of the LPBF AlSi10Mg is further reduced to 2.19 μm. Due to the properties of the viscous layer, such an ECMP method is only suitable for the AlSi10Mg but not the HR-2 to further reduce the surface roughness as the ECMP LPBF HR-2 surface quality deteriorated from 1.73 to 2.51 μm.
Graphical Abstract
Similar content being viewed by others
Change history
11 February 2023
A Correction to this paper has been published: https://doi.org/10.1007/s10800-023-01857-4
References
Wu MW, Chen JK, Chang PM, Ni K (2021) Compression deformation and fracture behaviors of laser powder bed fusion ti-6al-4v cellular solid during in situ tests. Mater Lett 303:130462. https://doi.org/10.1016/j.matlet.2021.130462
Pandey PM, Reddy NV, Dhande SG (2003) Slicing procedures in layered manufacturing: a review. Rapid Prototyp J 9:274–288. https://doi.org/10.1108/13552540310502185
King WE, Anderson AT, Ferencz RM, Hodge NE, Kamath C, Khairallah SA et al (2015) Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges. Appl Phys Rev 2:041304. https://doi.org/10.1063/1.4937809
Kumar P (2021) Fracture toughness of 304l austenitic stainless steel produced by laser powder bed fusion. Scripta Mater 202:114002. https://doi.org/10.1016/j.scriptamat.2021.114002
Jia Q, Rometsch P, Kürnsteiner P, Chao Q, Huang A, Weyland M et al (2019) Selective laser melting of a high strength al-mn-sc alloy: alloy design and strengthening mechanisms. Acta Mater 171:108–118. https://doi.org/10.1016/j.actamat.2019.04.014
Zhang LC, Attar H (2016) Selective laser melting of titanium alloys and titanium matrix composites for biomedical applications: a review. Adv Eng Mater 18:463–475. https://doi.org/10.1002/adem.201500419
Prabha P, Filomena S, Sebastian P et al (2022) A study of the influence of novel scan strategies on residual stress and microstructure of L-shaped LPBF IN718 samples. Mater Des 214:110386. https://doi.org/10.1016/j.matdes.2022.110386
Bi J, Lei Z, Chen Y, Chen X, Lu N, Tian Z et al (2021) An additively manufactured al-14.1 mg-0.47si-0.31sc-0.17zr alloy with high specific strength, good thermal stability and excellent corrosion resistance. J Mater Sci Technol 67:23–35. https://doi.org/10.1016/j.jmst.2020.06.036
Za S, Mk M (2021) Recent advances in nanostructured SnLn mixed-metal oxides as sunlight-activated nanophotocatalyst for high-efficient removal of environmental pollutants. Ceram Int 47:23702–23724. https://doi.org/10.1016/j.ceramint.2021.05.155
Za S, Sm M, Amiri O, Sn M, Kf L et al (2020) Nd2Sn2O7 nanostructures: green synthesis and characterization using date palm extract, a potential electrochemical hydrogen storage material. Ceram Int 46:17186–17196. https://doi.org/10.1016/j.ceramint.2020.03.014
Gu D, Shen Y (2009) Balling phenomena in direct laser sintering of stainless steel powder: metallurgical mechanisms and control methods. Mater Des 30:2903–2910. https://doi.org/10.1016/j.matdes.2009.01.013
Mumtaz K, Hopkinson N (2009) Top surface and side roughness of inconel 625 parts processed using selective laser melting. Rapid Prototyp J 15:96–103. https://doi.org/10.1108/13552540910943397
Meier C, Weissbach R, Weinberg J, Wall WA, Hart AJ (2018) Critical influences of particle size and adhesion on the powder layer uniformity in metal additive manufacturing. J Mater Process Tech 266:484–501. https://doi.org/10.1016/j.jmatprotec.2018.10.037
Han Q, Gu Y, Soe S, Lacan F, Setchi R (2019) Effect of hot cracking on the mechanical properties of hastelloy x superalloy fabricated by laser powder bed fusion additive manufacturing. Opt Laser Technol 124:105984. https://doi.org/10.1016/j.optlastec.2019.105984
Todd I (2017) Metallurgy: no more tears for metal 3d printing. Nature 549:342–343. https://doi.org/10.1038/549342a
Yang Y, Lu J, Luo Z, Wang D (2012) Accuracy and density optimization in directly fabricating customized orthodontic production by selective laser melting. Rapid Prototyp J 18:482–489. https://doi.org/10.1108/13552541211272027
Huttunen SE, Heino V, Vaajoki A, Hakala TJ, Ronkainen H (2019) Wear of additively manufactured tool steel in contact with aluminium alloy. Wear 432–433:202934. https://doi.org/10.1016/j.wear.2019.202934
Uzan NE, Ramati S, Shneck R, Frage N, Yeheskel O (2018) On the effect of shot-peening on fatigue resistance of alsi10mg specimens fabricated by additive manufacturing using selective laser melting (am-slm). Addit Manuf 21:458–464. https://doi.org/10.1016/j.addma.2018.03.030
Bhaduri D, Penchev P, Batal A, Dimov S, Soo SL, Sten S et al (2017) Laser polishing of 3d printed mesoscale components. Appl Surf Sci 405:29–46. https://doi.org/10.1016/j.apsusc.2017.01.211
Lee JY, Nagalingam AP, Yeo SH (2021) A review on the state-of-the-art of surface finishing processes and related iso/astm standards for metal additive manufactured components. Virtual Phys Prototy 16:68–96. https://doi.org/10.1080/17452759.2020.1830346
Yczkowska WE, Pawe L, Nawrat G (2020) Electrochemical polishing of austenitic stainless steels. Materials 13:2557. https://doi.org/10.3390/ma13112557
Dong G, Marleau FJ, Zhao YF (2019) Investigation of electrochemical post-processing procedure for ti-6al-4v lattice structure manufactured by direct metal laser sintering (dmls). Int J Adv Manuf Tech 104:3401–3417. https://doi.org/10.1007/s00170-019-03996-5
Zhang B, Li XH, Bai J, Guo J, Pan W, Sun CN et al (2017) Study of selective laser melting (slm) inconel 718 part surface improvement by electrochemical polishing. Mater Des 116:531–537. https://doi.org/10.1016/j.matdes.2016.11.103
Chang S, Liu A, Ong CYA, Zhang L, Huang X, Tan YH et al (2019) Highly effective smoothening of 3d-printed metal structures via overpotential electrochemical polishing. Mater Res Lett 7:282–289. https://doi.org/10.1080/21663831.2019.1601645
Mingear J, Zhang B, Hartl D, Elwany A (2019) Effect of process parameters and electropolishing on the surface roughness of interior channels in additively manufactured nickel-titanium shape memory alloy actuators. Addit Manuf 27:565–575. https://doi.org/10.1016/j.addma.2019.03.027
Kim US, Park JW (2019) High-quality surface finishing of industrial three-dimensional metal additive manufacturing using electrochemical polishing. Int J Pr Eng Man-GT 6:11–21. https://doi.org/10.1007/s40684-019-00019-2
Wen P, Qin Y, Chen Y, Voshage M, Jauer L, Poprawe R et al (2019) Laser additive manufacturing of zn porous scaffolds: shielding gas flow, surface quality and densification. J Mater Sci Technol 35:368–376. https://doi.org/10.1016/j.jmst.2018.09.065
Wang D, Yang Y, Yi Z, Su X (2013) Research on the fabricating quality optimization of the overhanging surface in slm process. Int J Adv Manuf Tech 65:1471–1484. https://doi.org/10.1007/s00170-012-4271-4
Zhang Y, Li J, Che S et al (2020) Electrochemical Polishing of Additively Manufactured Ti–6Al–4V Alloy[J]. Met Mater Int 26:783–792. https://doi.org/10.1007/s12540-019-00556-0
Tailor PB, Agrawal A, Joshi SS (2015) Numerical modeling of passive layer formation and stabilization in electrochemical polishing process. J Manuf Process 18:107–116. https://doi.org/10.1016/j.jmapro.2015.02.001
Tyagi P, Goulet T, Riso C, Stephenson R 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
Bai Y, Zhao C, Yang J et al (2020) Dry mechanical-electrochemical polishing of selective laser melted 316l stainless steel. Mater Des 193:108840. https://doi.org/10.1016/j.matdes.2020.108840
Kumar SA, Reddy SA, Mathias S, Shrivastava A, Raghupatruni P et al (2021) Investigation on pulsed electrolytically polished AlSi10Mg alloy processed via selective laser melting technique. P i mech eng l-j mat 12:1–13. https://doi.org/10.1177/14644207211045301
Defanti S, Denti L, Vincenzi N, Gatto A (2020) Preliminary assessment of electro-chemical machining for aluminum parts produced by laser-based powder bed fusion. Smart Sustain Manuf 4:122–134. https://doi.org/10.1520/SSMS20200039
Aboulkhair NT, Everitt NM, Ashcroft I, Tuck C (2014) Reducing porosity in alsi10mg parts processed by selective laser melting. Addit Manuf 1–4:77–86. https://doi.org/10.1016/j.addma.2014.08.001
Tradowsky U, White J, Ward RM, Read N, Reimers W, Attallah MM (2016) Selective laser melting of alsi10mg: influence of post-processing on the microstructural and tensile properties development. Mater Des 105:212–222. https://doi.org/10.1016/j.matdes.2016.05.066
Wang F, Zhang X, Deng H (2019) A comprehensive study on electrochemical polishing of tungsten. Appl Surf Sci 475:587–597. https://doi.org/10.1016/j.apsusc.2019.01.020
Han W, Fang F (2019) Fundamental aspects and recent developments in electropolishing. Int J Mach Tool Manu 139:1–23. https://doi.org/10.1016/j.ijmachtools.2019.01.001
Jacquet PA (1936) On the anodic behavior of copper in aqueous solutions of orthophosphoric acid. J Electrochem Soc 69:629. https://doi.org/10.1149/1.3498234
Hryniewicz T, Rokosz K (2010) Analysis of xps results of aisi 316l ss electropolished and magnetoelectropolished at varying conditions. Surf Coat Tech 204:2583–2592. https://doi.org/10.1016/j.surfcoat.2010.02.005
Abouelata A, Attia A, Youssef GI (2022) Electrochemical polishing versus mechanical polishing of aisi 304: surface and electrochemical study. J Solid State Electr 26:121–129. https://doi.org/10.1007/s10008-021-05037-2
Habibzadeh S, Ling L, Shum TD, Davis EC, Omanovic S (2014) Electrochemical polishing as a 316l stainless steel surface treatment method: towards the improvement of biocompatibility. Corros Sci 87:89–100. https://doi.org/10.1016/j.corsci.2014.06.010
Acknowledgements
The authors are grateful for the financial support from the National Natural Science Foundation of China (No.52175444, 51905506), the Sichuan Science and Technology Program (2021JDJQ0014), the Innovation and Development Foundation of CAEP (CX20210006).
Author information
Authors and Affiliations
Corresponding authors
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
The original online version of this article was revised: The co-corresponding authorship for the author Minheng Ye is updated.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Yu, Z., Liu, H., Ye, Z. et al. A comparison study of the electrochemical polishing of laser powder bed fusion HR-2 stainless steel and AlSi10Mg. J Appl Electrochem 53, 1157–1166 (2023). https://doi.org/10.1007/s10800-022-01843-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10800-022-01843-2