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Variations in the Surface Integrity of Ti-6Al-4V by Combinations of Additive and Subtractive Manufacturing Processes
Roland Bejjani1, Erik Bamford2, Stefan Cedergren2
1Department of Mechanical Engineering, Lebanese American University, Byblos 36, Lebanon.
Materials (Basel, Switzerland)
|April 17, 2020
Summary
Additive manufacturing (AM) and subtractive manufacturing (SM) significantly impact surface integrity. Different AM processes create unique microstructures, altering material properties even after finishing with SM.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Surface Engineering
Background:
- Additive manufacturing (AM) is increasingly adopted across industries, including aerospace.
- AM processes influence critical material properties like microstructure, residual stress, and surface topography.
- Subtractive manufacturing (SM) is often required for precision finishing, further modifying surface characteristics.
Purpose of the Study:
- To investigate the surface integrity of Ti-6Al-4V alloy parts produced by three AM methods followed by an SM step.
- To understand how different AM processes and subsequent SM affect the final surface integrity.
- To compare the surface integrity of AM/SM parts with conventionally manufactured reference material.
Main Methods:
- Manufacturing of Ti-6Al-4V parts using three distinct additive manufacturing techniques.
- Application of a subtractive manufacturing (machining) process for finishing the AM parts.
- Analysis of surface integrity, including microstructure and topography, after the combined AM/SM processes.
Main Results:
- Each additive manufacturing method resulted in distinct microstructures and affected material properties differently.
- The subtractive manufacturing step further modified the surface integrity, with variations observed based on the preceding AM process.
- Significant differences in surface integrity were found between parts produced by different AM/SM combinations and the conventionally manufactured reference material.
Conclusions:
- The choice of additive manufacturing process critically influences the resulting microstructure and surface integrity.
- Subtractive manufacturing finishing interacts with the AM-induced microstructure, leading to varied surface integrity outcomes.
- Understanding these process-material interactions is crucial for optimizing AM/SM workflows for specific applications, particularly in demanding sectors like aerospace.
