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Concurrent improvement of surface roughness and residual stress of as-built and aged additively manufactured maraging steel post-processed by milling

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Abstract

Laser Powder Bed Fusion (LPBF) technology enables the layerwise manufacturing of high-performance materials with different build orientations and shapes. However, even with the potential to improve primary mechanical properties and surface finishing depending on the process parameters, additional post-processing can be required to meet tight application requisites, mainly related to the surface roughness and residual stress. This study examined the concurrent effects of the build orientation (XYZ, XYZ-45, and YZX) on the LPBF manufacturing combined with the post-process steps of aging treatment (480 °C for 3 h) and milling with different cutting speeds and feed per tooth on the surface condition of maraging steel samples. Experimental tests followed by statistical analyses regarding the average roughness and residual stress allow identifying cause and effect mechanisms that affected the samples’ surface finishing and residual stresses. The main changes were related to mechanical anisotropy and layers arrangement of the maraging steel produced by LPBF and milled with different sample conditions, build orientations, and cutting parameters. The best average roughness of 0.37 ± 0.09 μm could be achieved with fz = 0.02 mm/tooth and vc = 250 m/min on the aged XYZ sample that also had a surface compressive stress of -690 MPa. Moreover, as-built and aged XYZ-45 and YZX samples could change from a tensile behavior obtained with LPBF to a compressive one when milled with fz = 0.02 mm/tooth due to concurrent effects of LPBF, heat treatment, and milling processes.

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Acknowledgments

The authors are grateful to André Luiz Jardini Munhoz (National Institute of Biofabrication - BIOFABRIS, Campinas, Brazil), Alisson Denis Carros Nizes (Thyssenkrupp Brasil Ltda. Division Springs & Stabilizers, Brazil), Anibal de Andrade Mendes Filho, and Osmando Cardoso.

Funding

This study is supported by the project grant #2018/11282-0, São Paulo Research Foundation (FAPESP). This study was financed in part by the Coordenação de Aperfeiçoamento de Pessoal de Nível Superior - Brasil (CAPES) - Finance Code 001.

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  1. Federal University of ABC, Engineering, Modeling and Applied Social Sciences Center, Av. dos Estados, 5001, Santo André, SP, 09210-580, Brazil

    Amanda Rossi de Oliveira & Erik Gustavo Del Conte

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  1. Amanda Rossi de Oliveira
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Correspondence to Amanda Rossi de Oliveira.

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de Oliveira, A.R., Del Conte, E.G. Concurrent improvement of surface roughness and residual stress of as-built and aged additively manufactured maraging steel post-processed by milling. Int J Adv Manuf Technol 116, 2309–2323 (2021). https://doi.org/10.1007/s00170-021-07527-z

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