Numerical and Experimental Analysis of Dual-Beam Laser Polishing Additive Manufacturing Ti6Al4V

Laser polishing is an emerging efficient technique to remove surface asperity without polluting the environment. However, the insufficient understanding of the mechanism of laser polishing has limited its practical application in industry. In this study, a dual-beam laser polishing experiment was carried out to reduce the roughness of a primary Ti6Al4V sample, and the polishing mechanism was well studied using simulation analysis. The results showed that the surface roughness of the sample was efficiently reduced from an initial 10.96 μm to 1.421 μm using dual-beam laser processing. The simulation analysis regarding the evolution of material surface morphology and the flow behavior of the molten pool during laser the polishing process revealed that the capillary force attributed to surface tension was the main driving force for flattening the large curvature surface of the molten pool at the initial stage, whereas the thermocapillary force influenced from temperature gradient played the key role of eliminating the secondary roughness at the edge of the molten pool during the continuous wave laser polishing process. However, the effect of thermocapillary force can be ignored during the second processing stage in dual-beam laser polishing. The simulation result is well in agreement with the experimental result, indicating the accuracy of the mechanism for the dual-beam laser polishing process. In summary, this work reveals the effect of capillary force and thermocapillary force on molten pool flows during the dual-beam laser polishing processes. Moreover, it is also proved that the dual-beam laser polishing process can further reduce the surface roughness of a sample and obtain a smoother surface.