Advances in polishing of internal structures on parts made by laser-based powder bed fusion

Abstract

The internal structures of metallic products are important in realizing functional applications. Considering the manufacturing of inner structures, laser-based powder bed fusion (L-PBF) is an attractive approach because its layering principle enables the fabrication of parts with customized interior structures. However, the inferior surface quality of L-PBF components hinders its productization progress seriously. In this article, process, basic forms, and applications relevant to L-PBF internal structures are reviewed comprehensively. The causes of poor surface quality and differences in the microstructure and property of the surface features of L-PBF inner structures are presented to provide a perspective of their surface characteristics. Various polishing technologies for L-PBF components with inner structures are presented, whereas their strengths and weaknesses are summarized along with a discussion on the challenges and prospects for improving the interior surface quality of L-PBF parts.

Graphical abstract

Keywords

laser-based powder bed fusion / polishing / internal structures / surface quality / surface features / post process / additive manufacturing

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Nomenclature

3D	Three-dimensional
AFM	Abrasive flow machining
AFP	Abrasive fluid polishing
AM	Additive manufacturing
BCC	Body-centered cubic
BF	Barrel finishing
CAD	Computer-aided design
CP	Chemical polishing
ECMP	Electrochemical mechanical polishing
EP	Electropolishing
HCAF	Hydrodynamic cavitation abrasive finishing
LAM	Laser additive manufacturing
LMD	Laser melting deposition
L-PBF	Laser-based powder bed fusion
LS	Laser sintering
MAF	Magnetic abrasive finishing

Acknowledgements

This publication has emanated from research supported by the Science Foundation Ireland (Grant Nos. 16/RC/3872 and 15/RP/B3208). For the purpose of Open Access, the authors have applied a CC BY public copyright license to any Author Accepted Manuscript version arising from the submission. The authors would like to thank the “111” Project by the State Administration of Foreign Experts Affairs and the Ministry of Education of China (Grant No. B07014).

Funding note

Open Access funding provided by the IReL Consortium.

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