Finishing Additively Manufactured Ti6Al4V Alloy with Low-Energy Electrical Discharges

Additive manufacturing has garnered significant interest in various industries due to its flexibility and capability to produce parts with complex shapes. However, issues related to surface quality, such as roughness and microstructural defects, necessitate the use of post-processing techniques to achieve the desired properties. Ti6Al4V alloy, produced additively, was finished using low-energy discharges, and the new surface integrity properties resulting from the induced heat energy were investigated. To further understand the influence of discharge energy on the formation of the new layer, roughness parameters and power spectral density were used to characterize the surface topography. SEM and EDS analyses were performed to examine the morphology and microstructural defects such as microcracks. The results indicate that the heat energy induced by the discharge improved the properties of the surface. SEM analysis revealed that the new layer was characterized by a reduction in defects such as unmelted particles, the balling effect, and microcracks. At the lowest investigated discharge energy of E = 0.21 mJ, surface roughness, Sa, was reduced by about 69%, which is equal to about 2 μm, accompanied by a significant decrease in microcracks. EDS analysis indicated that the diffusion of copper and zinc from the electrode to the top surface was related to the discharge energy. Furthermore, prediction models of the influence of wire electrical discharge polishing parameters, including discharge energy, wire speed, and time interval, on the surface roughness and material removal rate (MRR) were developed using the response surface methodology.