The adoption of metal Additive Manufacturing (AM) technologies to solve current and future engineering challenges has in the process drawn attention to fundamental deficiencies in these components. Among the intrinsic challenges that AM has to overcome, extremely rough surfaces is one of pivotal importance. AM surfaces are primarily composed of partially melted/sintered powder and melt pool layering. These rough surfaces are not just aesthetically unattractive, but also present defects that are known to prompt early failure under mechanical stress. There is a need to develop new surface finishing techniques capable of refining the appearance of the AM-produced components while removing defects and improving mechanical performance. The presentation will be focused on surface finishing techniques that have demonstrated the ability to improve the surface of AM components, bending fatigue resistance and tensile strength properties. This discussion will be targeting the surface finishing solutions for biomedical and aerospace applications, but other industries can highly benefit from this technology. In addition, the surface textures of these components and the use of Chemically Accelerated Vibratory Finishing (CAVF) to achieve an improved surface will be explained. The CAVF process is a chemical-mechanical surface treatment (known as ISF®, an isotropic superfinishing) that is capable of: (a) accommodating a wide range of shapes, including complex geometries; (b) polishing surfaces; (c) removal of loose powder particles inherently concerning to the aerospace industry as potentially damaging foreign object debris (FOD); (d) removal of structural support artifacts produced during the printing process; (e) improving the mechanical strength of the components.
- Understand the origin of the surface texture on additive manufactured components, and how to optimize them.
- Understand the benefits of surface finishing (post-processing) and the impact that it has on mechanical performance.
- Understand new technologies in surface finishing (post-processing); specifically designed for AM produced parts.