增材制造复杂金属构件表面抛光技术

doi:10.7527/S1000-6893.2021.25202

Abstract

Abstract: Additive manufacturing can meet the requirements of high complexity, high performance, light weight and multi-function of parts in the aerospace field. However, when manufacturing complex metal parts, it still has the shortcomings in terms of comprehensive performance, surface quality and forming accuracy, and the metal parts after additive manufacturing must be finished to meet the requirements of high use performance of aerospace parts. The principles, methods and application status of four highly accessible polishing technologies including chemical polishing, electrolytic polishing, abrasive flow polishing and laser polishing are introduced in this paper. Then, the development trend of surface polishing technology for additive manufacturing of metal parts is analyzed. Finally, a summary and prospects of additive manufacturing are given. The process optimization thought of combining additive manufacturing and surface polishing process is put forward, and it is pointed out that the development of green and intelligent integrated technical equipment is the major challenge facing us at present.

Key words: aerospace, additive manufacturing, surface quality, complex metal component, surface polishing technology

CLC Number:

V261.93
V461

YAO Yansheng, ZHOU Ruigen, ZHANG Chenglin, MEI Tao, WU Min. Surface polishing technology for additive manufacturing of complex metal components[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022, 43(4): 525202-525202.

References

[1] 顾冬冬, 张红梅, 陈洪宇, 等. 航空航天高性能金属材料构件激光增材制造[J]. 中国激光, 2020, 47(5):32-55. GU D D, ZHANG H M, CHEN H Y, et al. Laser additive manufacturing of high-performance metallic aerospace components[J]. Chinese Journal of Lasers, 2020, 47(5):32-55(in Chinese).
[2] 田宗军, 顾冬冬, 沈理达, 等. 激光增材制造技术在航空航天领域的应用与发展[J]. 航空制造技术, 2015, 58(11):38-42. TIAN Z J, GU D D, SHEN L D, et al. Application and development of laser additive manufacturing technology in aeronautics and astronautics[J]. Aeronautical Manufacturing Technology, 2015, 58(11):38-42(in Chinese).
[3] ZHU J H, ZHOU H, WANG C, et al. A review of topology optimization for additive manufacturing:Status and challenges[J]. Chinese Journal of Aeronautics, 2021, 34(1):91-110.
[4] KLINGVALL EK R, RÄNNAR L E, BÄCKSTÖM M, et al. The effect of EBM process parameters upon surface roughness[J]. Rapid Prototyping Journal, 2016, 22(3):495-503.
[5] ZHENG L J, LIU Y Y, SUN S B, et al. Selective laser melting of Al-8.5Fe-1.3V-1.7Si alloy:Investigation on the resultant microstructure and hardness[J]. Chinese Journal of Aeronautics, 2015, 28(2):564-569.
[6] CHEN Z E, WU X H, TOMUS D, et al. Surface roughness of selective laser melted Ti-6Al-4V alloy components[J]. Additive Manufacturing, 2018, 21:91-103.
[7] CHEN J, HOU W, WANG X Z, et al. Microstructure, porosity and mechanical properties of selective laser melted AlSi₁₀Mg[J]. Chinese Journal of Aeronautics, 2020, 33(7):2043-2054.
[8] QIU C L, YUE S, ADKINS N J E, et al. Influence of processing conditions on strut structure and compressive properties of cellular lattice structures fabricated by selective laser melting[J]. Materials Science and Engineering:A, 2015, 628:188-197.
[9] STIMPSON C K, SNYDER J C, THOLE K A, et al. Roughness effects on flow and heat transfer for additively manufactured channels[J]. Journal of Turbomachinery, 2016, 138(5):051008.
[10] 张军伟, 周超, 侯文博, 等. 金属医疗器械化学抛光研究进展[J]. 电镀与涂饰, 2018, 37(11):514-518. ZHANG J W, ZHOU C, HOU W B, et al. Progress on research of chemical polishing for metal medical devices[J]. Electroplating & Finishing, 2018, 37(11):514-518(in Chinese).
[11] PYKA G, KERCKHOFS G, PAPANTONIOU I, et al. Surface roughness and morphology customization of additive manufactured open porous Ti₆Al₄V structures[J]. Materials, 2013, 6(10):4737-4757.
[12] 李晓丹, 李建中, 倪家强, 等. 激光增材制造钛合金构件的化学抛光工艺研究[J]. 航空制造技术, 2020, 63(10):66-71. LI X D, LI J Z, NI J Q, et al. Chemical polishing of titanium alloy shaped by laser additive manufacturing[J]. Aeronautical Manufacturing Technology, 2020, 63(10):66-71(in Chinese).
[13] 郭怡东, 马玉娥, 李佩谣. 增材制造钛合金微桁架夹芯板低速冲击响应[J]. 航空学报, 2021, 42(2):423820. GUO Y D, MA Y E, LI P Y. Low velocity impact response of additively manufactured titanium alloy micro-truss sandwich panels[J]. Acta Aeronautica et Astronautica Sinica, 2021, 42(2):423820(in Chinese).
[14] ŁYCZKOWSKA E, SZYMCZYK P, DYBAŁA B, et al. Chemical polishing of scaffolds made of Ti-6Al-7Nb alloy by additive manufacturing[J]. Archives of Civil and Mechanical Engineering, 2014, 14(4):586-594.
[15] LHUISSIER P, DE FORMANOIR C, MARTIN G, et al. Geometrical control of lattice structures produced by EBM through chemical etching:Investigations at the scale of individual struts[J]. Materials & Design, 2016, 110:485-493.
[16] DE FORMANOIR C, SUARD M, DENDIEVEL R, et al. Improving the mechanical efficiency of electron beam melted titanium lattice structures by chemical etching[J]. Additive Manufacturing, 2016, 11:71-76.
[17] WYSOCKI B, IDASZEK J, BUHAGIAR J, et al. The influence of chemical polishing of titanium scaffolds on their mechanical strength and in-vitro cell response[J]. Materials Science and Engineering:C, 2019, 95:428-439.
[18] VAN HOOREWEDER B, LIETAERT K, NEIRINCK B, et al. CoCr F75 scaffolds produced by additive manufacturing:Influence of chemical etching on powder removal and mechanical performance[J]. Journal of the Mechanical Behavior of Biomedical Materials, 2017, 68:216-223.
[19] BALYAKIN A V, SHVETCOV A N, ZHUCHENKO E I. Chemical polishing of samples obtained by selective laser melting from titanium alloy Ti₆Al₄V[J]. MATEC Web of Conferences, 2018, 224:01031.
[20] WYSOCKI B, IDASZEK J, ZDUNEK J, et al. The influence of selective laser melting (SLM) process parameters on in-vitro cell response[J]. International Journal of Molecular Sciences, 2018, 19(6):1619.
[21] PERSENOT T, MARTIN G, DENDIEVEL R, et al. Enhancing the tensile properties of EBM as-built thin parts:Effect of HIP and chemical etching[J]. Materials Characterization, 2018, 143:82-93.
[22] MOHAMMAD A E K, WANG D W. Electrochemical mechanical polishing technology:Recent developments and future research and industrial needs[J]. The International Journal of Advanced Manufacturing Technology, 2016, 86(5-8):1909-1924.
[23] KIM S H, LEE S G, CHOI S G, et al. A study on the characteristics of micro electropolishing for stainless steel[J]. Advanced Materials Research, 2011, 328-330:474-477.
[24] LEE E S. Machining characteristics of the electropolishing of stainless steel (STS316L)[J]. The International Journal of Advanced Manufacturing Technology, 2000, 16(8):591-599.
[25] HAN W, FANG F Z. Fundamental aspects and recent developments in electropolishing[J]. International Journal of Machine Tools and Manufacture, 2019, 139:1-23.
[26] LASSELL A. The electropolishing of electron beam melting, additively manufactured TI6AL4V titanium:Relevance, process parameters and surface finish[D]. Louisvlle:University of Louisville, 2016.
[27] ZHANG Y F, LI J Z, CHE S H, et al. Electrochemical polishing of additively manufactured Ti-6Al-4V alloy[J]. Metals and Materials International, 2020, 26(6):783-792.
[28] GODDARD A J, HARRIS R C, SALEEM S, et al. Electropolishing and electrolytic etching of Ni-based HIP consolidated aerospace forms:A comparison between deep eutectic solvents and aqueous electrolytes[J]. Transactions of the IMF, 2017, 95(3):137-146.
[29] PROTSENKO V S, BUTYRINA T E, BOBROVA L S, et al. Enhancing corrosion resistance of nickel surface by electropolishing in a deep eutectic solvent[J]. Materials Letters, 2020, 270:127719.
[30] NESTLER K, BÖTTGER-HILLER F, ADAMITZKI W, et al. Plasma electrolytic polishing-an overview of applied technologies and current challenges to extend the polishable material range[J]. Procedia CIRP, 2016, 42:503-507.
[31] URLEA V, BRAILOVSKI V. Electropolishing and electropolishing-related allowances for powder bed selectively laser-melted Ti-6Al-4V alloy components[J]. Journal of Materials Processing Technology, 2017, 242:1-11.
[32] LOHSER J R. Evaluation of electrochemical and laser polishing of selectively LaserMelted 316L stainless steel[D]. San Luis Obispo:Cal Poly, 2018.
[33] MINGEAR J, ZHANG B, HARTL D, et al. Effect of process parameters and electropolishing on the surface roughness of interior channels in additively manufactured nickel-titanium shape memory alloy actuators[J]. Additive Manufacturing, 2019, 27:565-575.
[34] TYAGI P, GOULET T, RISO C, et al. Reducing the roughness of internal surface of an additive manufacturing produced 316 steel component by chempolishing and electropolishing[J]. Additive Manufacturing, 2019, 25:32-38.
[35] CHANG S, LIU A H, ONG C Y A, et al. Highly effective smoothening of 3D-printed metal structures via overpotential electrochemical polishing[J]. Materials Research Letters, 2019, 7(7):282-289.
[36] FU Y Z, WANG X P, GAO H, et al. Blade surface uniformity of blisk finished by abrasive flow machining[J]. The International Journal of Advanced Manufacturing Technology, 2016, 84(5-8):1725-1735.
[37] 赵路, 孙玉利, 施凯博, 等. 整体叶盘磨粒流加工仿真与试验研究[J]. 航空制造技术, 2019, 62(13):53-59. ZHAO L, SUN Y L, SHI K B, et al. Simulations and experiments on blisk by using abrasive flow machining[J]. Aeronautical Manufacturing Technology, 2019, 62(13):53-59(in Chinese).
[38] 高航, 李世宠, 付有志, 等. 金属增材制造格栅零件磨粒流抛光[J]. 航空学报, 2017, 38(10):421210. GAO H, LI S C, FU Y Z, et al. Abrasive flow machining of additively manufactured metal grilling parts[J]. Acta Aeronautica et Astronautica Sinica, 2017, 38(10):421210(in Chinese).
[39] LI J Y, YANG L F, LIU W N, et al. Experimental research into technology of abrasive flow machining nonlinear tube runner[J]. Advances in Mechanical Engineering, 2014, 6:752353.
[40] HAN S, SALVATORE F, RECH J, et al. Abrasive flow machining (AFM) finishing of conformal cooling channels created by selective laser melting (SLM)[J]. Precision Engineering, 2020, 64:20-33.
[41] 党稼宁, 雷力明, 石磊, 等. 增材制造燃油喷嘴特征件磨粒流抛光研究[J]. 航空制造技术, 2019, 62(7):79-83, 90. DANG J N, LEI L M, SHI L, et al. Study on abrasive flow machining of additive manufacturing fuel nozzle features[J]. Aeronautical Manufacturing Technology, 2019, 62(7):79-83, 90(in Chinese).
[42] UHLMANN E, SCHMIEDEL C, WENDLER J. CFD simulation of the abrasive flow machining process[J]. Procedia CIRP, 2015, 31:209-214.
[43] 李世宠. 增材制造格栅零件磨粒流抛光加工技术研究[D]. 大连:大连理工大学, 2017. LI S C. Study of abrasive flow machining technology for additively manufactured grille parts[D]. Dalian:Dalian University of Technology, 2017(in Chinese).
[44] ROSA B, MOGNOL P, HASCOËT J Y. Laser polishing of additive laser manufacturing surfaces[J]. Journal of Laser Applications, 2015, 27(S2):S29102.
[45] GORA W S, TIAN Y T, CABO A P, et al. Enhancing surface finish of additively manufactured titanium and cobalt chrome elements using laser based finishing[J]. Physics Procedia, 2016, 83:258-263.
[46] OBEIDI M A, MCCARTHY E, O'CONNELL B, et al. Laser polishing of additive manufactured 316L stainless steel synthesized by selective laser melting[J]. Materials, 2019, 12(6):991.
[47] BORDATCHEV E V, HAFIZ A M K, TUTUNEA-FATAN O R. Performance of laser polishing in finishing of metallic surfaces[J]. The International Journal of Advanced Manufacturing Technology, 2014, 73(1-4):35-52.
[48] PERRY T L, WERSCHMOELLER D, LI X C, et al. Pulsed laser polishing of micro-milled Ti₆Al₄V samples[J]. Journal of Manufacturing Processes, 2009, 11(2):74-81.
[49] FANG Z H, LU L B, CHEN L F, et al. Laser polishing of additive manufactured superalloy[J]. Procedia CIRP, 2018, 71:150-154.
[50] LAMIKIZ A, SÁNCHEZ J A, LÓPEZ DE LACALLE L N, et al. Laser polishing of parts built up by selective laser sintering[J]. International Journal of Machine Tools and Manufacture, 2007, 47(12-13):2040-2050.
[51] ROSA B, MOGNOL P, HASCOËT J Y. Modelling and optimization of laser polishing of additive laser manufacturing surfaces[J]. Rapid Prototyping Journal, 2016, 22(6):956-964.
[52] YUNG K C, XIAO T Y, CHOY H S, et al. Laser polishing of additive manufactured CoCr alloy components with complex surface geometry[J]. Journal of Materials Processing Technology, 2018, 262:53-64.
[53] 黄云, 肖贵坚, 邹莱. 整体叶盘抛光技术的研究现状及发展趋势[J]. 航空学报, 2016, 37(7):2045-2064. HUANG Y, XIAO G J, ZOU L. Current situation and development trend of polishing technology for blisk[J]. Acta Aeronautica et Astronautica Sinica, 2016, 37(7):2045-2064(in Chinese).
[54] GUO J, AU K H, SUN C N, et al. Novel rotating-vibrating magnetic abrasive polishing method for double-layered internal surface finishing[J]. Journal of Materials Processing Technology, 2019, 264:422-437.
[55] NAGALINGAM A P, YUVARAJ H K, YEO S H. Synergistic effects in hydrodynamic cavitation abrasive finishing for internal surface-finish enhancement of additive-manufactured components[J]. Additive Manufacturing, 2020, 33:101110.
[56] PYKA G, BURAKOWSKI A, KERCKHOFS G, et al. Surface modification of Ti₆Al₄V open porous structures produced by additive manufacturing[J]. Advanced Engineering Materials, 2012, 14(6):363-370.
[57] DONG G Y, MARLEAU-FINLEY J, ZHAO Y F. Investigation of electrochemical post-processing procedure for Ti-6Al-4V lattice structure manufactured by direct metal laser sintering (DMLS)[J]. The International Journal of Advanced Manufacturing Technology, 2019, 104(9-12):3401-3417.
[58] KERCKHOFS G, PYKA G, BAEL S, et al. Of the influence of surface roughness modification of bone tissue engineering scaffolds on the morhology and mechanical properties[C]//SkyScan User Meeting, 2010
[59] MOHAMMADIAN N, TURENNE S, BRAILOVSKI V. Surface finish control of additively-manufactured Inconel 625 components using combined chemical-abrasive flow polishing[J]. Journal of Materials Processing Technology, 2018, 252:728-738.
[60] BAI Y C, ZHAO C L, YANG J, et al. Dry mechanical-electrochemical polishing of selective laser melted 316L stainless steel[J]. Materials & Design, 2020, 193:108840.
[61] 庞桂兵. 电化学光整加工技术及在航空制造领域的应用探讨[J]. 航空制造技术, 2018, 61(3):26-32. PANG G B. Electrochemical finishing technology and its application in aviation manufacturing[J]. Aeronautical Manufacturing Technology, 2018, 61(3):26-32(in Chinese).
[62] YI R, ZHANG Y, ZHANG X Q, et al. A generic approach of polishing metals via isotropic electrochemical etching[J]. International Journal of Machine Tools and Manufacture, 2020, 150:103517.

Surface polishing technology for additive manufacturing of complex metal components

RichHTML

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

References

Related Articles 15

Recommended Articles

Metrics

Comments

[1]	Rui SI, Yong CHEN. Application trends of additive manufacturing technology for civil aircraft [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(5): 529677-529677.
[2]	Weihong ZHANG, Changhong TANG. Lightweighting of aerospace and aeronautical equipment: Challenges and perspectives [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(5): 529965-529965.
[3]	Meng CHEN, Rumeng LIU, Lifeng WANG, Yazhong LUO, Tao SUO, Chong PAN, Panfeng ZHANG, Guoxuan DONG, Haiyan HU. Connotation and key research areas of new application code “Aerospace Mechanics” of the National Natural Science Foundation of China [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(2): 129947-129947.
[4]	Zhongzhi LI, Jinyi MA, Jianliang AI, Yiqun DONG. Fault detection and classification of aerospace sensors using deep neural networks finetuned from VGG16 [J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(S1): 727615-727615.
[5]	Weihong ZHANG, Han ZHOU, Shaoying LI, Jihong ZHU, Lu ZHOU. Material⁃structure integrated design for high⁃performance aerospace thin⁃walled component [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2023, 44(9): 627428-627428.
[6]	Zhongqin LIN, Zhongqi YU, Donghua DAI, Xiaoguang FAN, Shengfu YU, Dongdong GU, Shuhui LI, Yusheng SHI. Development and prospect of metal spinning: Additive hybrid manufacturing technology for complex thin⁃walled component with high ribs [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2023, 44(9): 627493-627493.
[7]	Lun TANG, Shengfu YU, Bo ZHENG, Yusheng SHI, Ying CHEN. Development and application of in⁃situ Al₂O₃ aluminum alloy powder core wire for cylindrical lattice [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2023, 44(9): 626864-626864.
[8]	Linhong ZHOU, Guangyu HE, Shunlai ZANG. A method for modeling three-dimensional morphology of dust particle based on cross-sectional SEM data characteristics [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2023, 44(4): 426201-426201.
[9]	Mengqi GU, Jiacai ZHU, Wanlin GUO, Song XUE. Prospects for fatigue durability and reliability of reusable launch vehicle structures [J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(23): 628299-628299.
[10]	Jiacheng ZHANG, Yuehe ZHU, Yazhong LUO. Space target rendezvous sequence planning via pointer networks [J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(15): 528698-528698.
[11]	Songcheng JIANG, Hui YANG, Yan WANG, Hong XIAO, Yongbin LIU, Chuanyang LI. Analysis of mechanical characteristics of flexible skin with tunable Poisson's ratio for morphing wing [J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(13): 227748-227748.
[12]	Zhiqiang ZHANG, Qingze GOU, Xuecheng LU, Hao WANG, Yiran CAO, Zhiyong GUO. Droplet transfer behavior of high strength aluminum alloy CMT+P arc additive manufacturing [J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(13): 427881-427881.
[13]	Guang MENG, Chang LIU, Dongchun YANG, Chenghong ZHOU, Hua ZHOU. First flight of SpaceX heavy-lift starship: Enlightenment for aerospace industry in China [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2023, 44(10): 28914-028914.
[14]	WU Rui, SHI Wenze, LU Chao, LI Qiufeng, CHEN Guo. Quantitative analysis method for electromagnetic ultrasonic SH guided wave detection of aerospace stainless steel sheet [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022, 43(9): 425888-425888.
[15]	ZHANG Zhouyu, CAO Yunfeng, FAN Yanming. Research progress of vision based aerospace conflict sensing technologies for small unmanned aerial vehicle in low altitude [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022, 43(8): 25645-025645.