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Abrasive and non-conventional post-processing techniques to improve surface finish of additively manufactured metals: a review

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Abstract

Metal additive manufacturing (MAM) has attracted global industry and academia due to its flexibility and ability to achieve complex geometry. The inherent rough surfaces are of concerns and need to be addressed to meet the strict requirement of critical engineering components. This paper reviews the working principles for common MAM processes and summarizes current post-processing techniques for surface finish improvement. Relevant finishing techniques using abrasives and non-conventional techniques, such as grinding, polishing, laser, peening, buffing, and electrochemical polishing are reviewed, and typical results are documented for different AM processes. Limitation of each process and enhancing techniques using magnetism, ultrasonic, and pulsed current for selected processes are presented. Post processing not only reduces surface roughness, but also contributes to dimensional and form tolerances, and prolongs long-term fatigue and creep life of AM metals. Although post-processing techniques can effectively remove surface defects to achieve submicron surface finish, controlling of surface defects that extend deeply below a surface is still a challenge. Future hybrid system that combines AM and a non-traditional post-process would meet the requirement for MAM.

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Abbreviations

AM:

Additive manufacturing

AFM:

Abrasive flow machining

ASTM:

American Society for Testing and Materials

BJ:

Binder jetting

CAD:

Computer-aided design

CBN:

Cubic boron nitride

CNC:

Computer numerical control

CNT:

Carbon nanotubes

CSAM:

Cold spray additive manufacturing

CSAM:

Cold spray additive manufacturing

DED:

Directed energy deposition

DMD:

Direct metal deposition

DMLS:

Direct metal laser sintering

EBFFF:

Electron beam free form fabrication

EBM:

Electron beam melting

ECDe:

Electrochemical deburring

ECF:

Electrochemical finishing

ECG:

Electrochemical grinding

ECH:

Electrochemical honing

ECM:

Electrochemical machining

ECP:

Electrochemical polishing

HRc:

Hardness Rockwell C

ISO:

International Organization for Standardization

LAM:

Laser additive manufacturing

LENS:

Laser engineered net shaping

LMD:

Laser metal deposition

LOF:

Lack of fusion

LRM:

Laser rapid manufacturing

MAF:

Magnetic abrasive finishing

MAM:

Metal additive manufacturing

ME:

Material extrusion

MJ:

Material jetting

MQL:

Minimum quantity lubrication

MRR:

Material removal rate

ND:

Nano diamond

PBF:

Powder bed fusion

PTA:

Plasma transferred arc

Ra:

Arithmetical mean roughness (linear)

Sa:

Arithmetical mean roughness (area)

SL:

Sheet lamination

SLM:

Selective laser melting

SLS:

Selective laser sintering

UAM:

Ultrasonic additive manufacturing

VP:

Vat photopolymerization

WAAM:

Wire arc additive manufacturing

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Acknowledgements

The authors are grateful to Federal Agency for the Support and Improvement of Higher Education (CAPES), National Council for Scientific and Technological Development (CNPq), Minas Gerais State Research Foundation (FAPEMIG), and São Paulo Research Foundation (FAPESP). This work was supported by the São Paulo Research Foundation, award numbers: 2016/11309-0; 2019/00343-1; 2019/08926-6; 2020/03110-5, National Council for Scientific and Technological Development, award numbers: 308860/2017-9; 142055/2019-0 and Federal Agency for the Support and Improvement of Higher Education, award numbers: 001.

Funding

This work was supported by the São Paulo Research Foundation, award numbers: 2016/11309-0; 2019/00343-1; 2019/08926-6; 2020/03110-5, National Council for Scientific and Technological Development, award numbers: 308860/2017-9; 142055/2019-0 and Federal Agency for the Support and Improvement of Higher Education, award numbers: 001.

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  1. Department of Mechanical Engineering, University of Brasilia, Asa Norte, Brasília, DF, 70910-900, Brazil

    Déborah De Oliveira

  2. School of Mechanical Engineering, Federal University of Uberlandia, Campus Santa Monica, Uberlandia, MG, 38408-100, Brazil

    Milla Caroline Gomes & Marcio Bacci Da Silva

  3. Federal University of Catalao, Catalao, GO, Brazil

    Aline Gonçalves Dos Santos

  4. Department of Mechanical Engineering, University of Sao Paulo, Sao Carlos School of Engineering, Sao Carlos, SP, Brazil

    Kandice Suane Barros Ribeiro, Iago José Vasques & Reginaldo Teixeira Coelho

  5. Department of Engineering Technology and Industrial Distribution, Texas A&M University, College Station, TX, 77843, USA

    Nguyen Wayne Hung

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De Oliveira, D., Gomes, M.C., Dos Santos, A.G. et al. Abrasive and non-conventional post-processing techniques to improve surface finish of additively manufactured metals: a review. Prog Addit Manuf 8, 223–240 (2023). https://doi.org/10.1007/s40964-022-00325-3

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