Removing Alpha Case from Laser Powder Bed Fusion Components by Cavitation Abrasive Surface Finishing

Laser powder bed fusion (L-PBF) has become a highly viable method for manufacturing metal structural components for a variety of industries. Despite many attractive qualities, the rough surfaces of L-PBF components often necessitates post-processing treatments to improve the surface finish. Furthermore, heat treatments are generally necessary to control the microstructure and properties of L-PBF components, which can impart a detrimental surface oxide layer that requires removal. In this investigation, cavitation abrasive surface finishing (CASF) was adopted for the surface treatment of Ti6Al4V components produced by L-PBF and removal of the surface oxide layer. The surface texture, residual stress, and material removal were evaluated over a range of treatment conditions and as a function of the target surface orientation. Results showed that CASF reduced the average surface roughness from the as-built condition (R_a ≈ 15 µm) to below 5 µm as well as imparted a surface compressive residual stress of up to 600 MPa. The CASF treatment removed the alpha case from direct line-of-sight surfaces under a range of treatment intensity. However, deep valleys and surfaces at large oblique angles of incidence (≥60°) proved challenging to treat uniformly. Overall, results suggest that CASF could serve as a potent alternative to chemical treatments for post-processing of L-PBF components of titanium and other metals. Further investigation is recommended for improving the process effectiveness and to characterize the fatigue performance of the treated metal.