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Cavitation Abrasive Surface Finishing and Peening: Fatigue Crack Resistance for Direct Metal Laser Sintering of Ti 6Al-4V

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The Boeing Company and Tohoku University are investigating the fatigue crack resistance performance that can be achieved using a new process for surface smoothing and peening of additive manufactured metal parts.  The method combines the techniques of water cavitation peening (CP) and an adapted form of water jetting.  The cavitation abrasive surface finishing and peening (CASF) process was initially devised as a means for eliminating the rough surface that results from additive manufacturing powder bed processes, but now it is being developed for other manufacturing needs, such as the removal of alpha case from the high-temperature oxide exposed surfaces of superplastic-formed titanium parts.  A substantial amount of testing has been accomplished to-date and the process has been found to be capable of removing the unwanted surface layer of as-deposited powder particles and smoothing surfaces sufficiently to meet the finishing requirements of equivalent metal aerospace design hardware built with legacy production processes.  One of the unique benefits of CASF is that the surface of the parts is also imparted with a compressive residual stress layer, which has been found effective in reducing the initiation of fatigue cracks.

Learning Objectives:

  • Have the tools necessary in order to understand whether or not the cavitation abrasive surface finishing and peening method would be of value for the AM parts they fabricate
  • Take away the possible performance improvement that CASF could offer for your business
  • Consider teaming opportunities for the further development of CASF with Boeing and its partners