Work

Polishing of EB-PBF Ti6Al4V Vertical Surfaces with Semi-Melted Particle Characteristics Realized by Continuous Laser

Year: 2025

Type: article

Abstract: Electron beam powder bed fusion (EB-PBF) Ti6Al4V often exhibits high vertical surface roughness, limiting its use in high-end applications. In this study, an infrared continuous-wave laser was applied to precisely polish the vertical surface. An orthogonal design identified the optimal condition as 10,400 kW/cm2 power density, 800 mm/s scanning speed, and one pass, achieving a minimum Sa of 0.24 μm and a 98.03% reduction compared with the as-built surface. To address the adhered semi-molten particle characteristics of EB-PBF sidewalls, a molten-pool-dynamics-based polishing model was developed and validated, yielding an error as low as 1.24%. Simulations indicate that power density governs the final morphology by controlling molten pool coverage, scanning speed affects polishing efficiency via thermocapillary force, and polishing time influences surface quality by triggering or avoiding melt splashing.

Source: Micromachines

DOI: 10.3390/mi17010046

Authors: Xiaozhu Chen, Congyi Wu, Youmin Rong, Guojun Zhang, Yu Huang

Institutions: State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology

Language: English

Topic: Additive Manufacturing Materials and Processes

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $2,534

Funders: Industrial Technology Research Institute, Basic and Applied Basic Research Foundation of Guangdong Province