Laser polishing of a high-entropy alloy manufactured by selective laser melting

Abstract

The selective laser melting (SLM) technique applied to high-entropy alloys (HEAs) has attracted considerable attention in recent years. However, its practical application has been restricted by poor surface quality. In this study, the capability of laser polishing on the rough surface of a Co-free HEA fabricated using SLM was examined. Results show that the initial SLM-manufactured (as-SLMed) surface of the Co-free HEA, with a roughness exceeding 3.0 μm, could be refined to less than 0.5 μm by laser polishing. Moreover, the microstructure, microhardness, and wear resistance of the laser-polished (LP-ed) zone were investigated. Results indicate that compared with the microhardness and wear resistance of the as-SLMed layer, those of the LP-ed layer decreased by 4% and 11%, respectively, because of the increase in grain size and reduction of the BCC phase. This study shows that laser polishing has an excellent application prospect in surface improvement of HEAs manufactured by SLM.

Graphical abstract

Keywords

laser polishing / selective laser melting / high-entropy alloy / surface roughness / mechanical performance

References

[1] Han C J, Fang Q H, Shi Y S, Tor S B, Chua C K, Zhou K. Recent advances on high-entropy alloys for 3D printing. Advanced Materials, 2020, 32(26): 1903855

[2] Li R D, Niu P D, Yuan T C, Cao P, Chen C, Zhou K C. Selective laser melting of an equiatomic CoCrFeMnNi high-entropy alloy: processability, non-equilibrium microstructure, and mechanical property. Journal of Alloys and Compounds, 2018, 746: 125–134

[3] Brif Y, Thomas M, Todd I. The use of high-entropy alloys in additive manufacturing. Scripta Materialia, 2015, 99: 93–96

[4] Ostovari Moghaddam A, Shaburova N A, Samodurova M N, Abdollahzadeh A, Trofimov E A. Additive manufacturing of high entropy alloys: a practical review. Journal of Materials Science and Technology, 2021, 77: 131–162

[5] Delgado J, Ciurana J, Rodríguez C A. Influence of process parameters on part quality and mechanical properties for DMLS and SLM with iron-based materials. The International Journal of Advanced Manufacturing Technology, 2012, 60(5–8): 601–610

[6] Yasa E, Deckers J, Kruth J P. The investigation of the influence of laser re-melting on density, surface quality, and microstructure of selective laser melting parts. Rapid Prototyping Journal, 2011, 17(5): 312–327

[7] Zhang B C, Zhu L, Liao H L, Coddet C. Improvement of surface properties of SLM parts by atmospheric plasma spraying coating. Applied Surface Science, 2012, 263: 777–782

[8] Hafiz A M K, Bordatchev E V, Tutunea-Fatan R O. Experimental analysis of applicability of a picosecond laser for micro-polishing of micromilled Inconel 718 superalloy. The International Journal of Advanced Manufacturing Technology, 2014, 70(9–12): 1963–1978

[9] Perez DeweyM, UlutanD. Development of laser polishing as an auxiliary post-process to improve surface quality in fused deposition modeling parts. In: Proceedings of the 12th ASME International Manufacturing Science and Engineering Conference. Los Angeles: ASME, 2017, V002T01A006

[10] Ma C P, Guan Y C, Zhou W. Laser polishing of additive manufactured Ti alloys. Optics and Lasers in Engineering, 2017, 93: 171–177

[11] Chen Y D, Tsai W J, Liu S H, Horng J B. Picosecond laser pulse polishing of ASP23 steel. Optics & Laser Technology, 2018, 107: 180–185

[12] Zhao L J, Cheng J, Chen M J, Yuan X D, Liao W, Liu Q, Yang H, Wang H J. Formation mechanism of a smooth, defect-free surface of fused silica optics using rapid CO₂ laser polishing. International Journal of Extreme Manufacturing, 2019, 1(3): 035001

[13] Liu H G, Xie L R, Lin W X, Hong M H. Optical quality laser polishing of CVD diamond by UV pulsed laser irradiation. Advanced Optical Materials, 2021, 9(21): 2100537

[14] Rosa B, Mognol P, Hascoët J Y. Laser polishing of additive laser manufacturing surfaces. Journal of Laser Applications, 2015, 27(S2): S29102

[15] Fang Z H, Lu L B, Chen L F, Guan Y C. Laser polishing of additive manufactured superalloy. Procedia CIRP, 2018, 71: 150–154

[16] Hofele M, Schanz J, Roth A, Harrison D K, De Silva A K M, Riegel H. Process parameter dependencies of continuous and pulsed laser modes on surface polishing of additive manufactured aluminium AlSi10Mg parts. Materials Science and Engineering Technology, 2021, 52(4): 409–432

[17] Li Y H, Wang B, Ma C P, Fang Z H, Chen L F, Guan Y C, Yang S F. Material characterization, thermal analysis, and mechanical performance of a laser-polished Ti alloy prepared by selective laser melting. Metals, 2019, 9(2): 112

[18] Miracle D B, Senkov O N. A critical review of high entropy alloys and related concepts. Acta Materialia, 2017, 122: 448–511

[19] Li Z M, Pradeep K G, Deng Y, Raabe D, Tasan C C. Metastable high-entropy dual-phase alloys overcome the strength-ductility trade-off. Nature, 2016, 534(7606): 227–230

[20] Zhao Y L, Yang T, Zhu J H, Chen D, Yang Y, Hu A, Liu C T, Kai J J. Development of high-strength Co-free high-entropy alloys hardened by nanosized precipitates. Scripta Materialia, 2018, 148: 51–55

[21] Vogiatzief D, Evirgen A, Pedersen M, Hecht U. Laser powder bed fusion of an Al-Cr-Fe-Ni high-entropy alloy produced by blending of prealloyed and elemental powder: process parameters, microstructures, and mechanical properties. Journal of Alloys and Compounds, 2022, 918: 165658

[22] Luo S C, Zhao C Y, Su Y, Liu Q, Wang Z M. Selective laser melting of dual phase AlCrCuFeNi_x high entropy alloys: formability, heterogeneous microstructures, and deformation mechanisms. Additive Manufacturing, 2020, 31: 100925

[23] Tan X J, Chen D H, Xu J B, Chen H T, Peng X Y, Guo L, Xiao H B, Zhang Q M. High strength Fe32Cr33Ni29Al3Ti3 fabricated by selective laser melting. Journal of Materials Research and Technology, 2023, 27: 3701–3711

[24] Zhou Y Q, Zhao Z Y, Zhang W, Xiao H B, Xu X M. Experiment study of rapid laser polishing of freeform steel surface by dual-beam. Coatings, 2019, 9(5): 324

[25] Xiao H B, Zhou Y Q, Liu M J, Xu X M. Laser polishing of tool steel using a continuous-wave laser assisted by a steady magnetic field. AIP Advances, 2020, 10(2): 025319

[26] Hammouti S, Pascale-Hamri A, Faure N, Beaugiraud B, Guibert M, Mauclair C, Benayoun S, Valette S. Wear rate control of peek surfaces modified by femtosecond laser. Applied Surface Science, 2015, 357: 1541–1551

[27] Mu Y K, Jia Y D, Xu L, Jia Y F, Tan X H, Yi J, Wang G, Liaw P K. Nano oxides reinforced high-entropy alloy coatings synthesized by atmospheric plasma spraying. Materials Research Letters, 2019, 7(8): 312–319

[28] Wang S, Li Y, Zhang D, Yang Y, Manladan S M, Luo Z. Microstructure and mechanical properties of high strength AlCoCrFeNi_2.1 eutectic high entropy alloy prepared by selective laser melting (SLM). Materials Letters, 2022, 310: 131511

[29] He X, Zhong L, Wang G R, Liao Y, Liu Q Y. Tribological behavior of femtosecond laser textured surfaces of 20CrNiMo/beryllium bronze tribo-pairs. Industrial Lubrication and Tribology, 2015, 67(6): 630–638

[30] Liu D R, Yan B, Shen B, Liu L, Hu W B. Friction behaviors of rough chromium surfaces under starving lubrication conditions. Applied Surface Science, 2018, 427: 857–862

[31] Wang Z, Zhao Q Z, Wang C W. Reduction of friction of metals using laser-induced periodic surface nanostructures. Micromachines, 2015, 6(11): 1606–1616

[32] Ma C P, Guan Y C, Zhou W. Laser polishing of additive manufactured Ti alloys. Optics and Lasers in Engineering, 2017, 93: 171–177

[33] Wang K, Xie D Q, Lv F, Liu F X, Liu R K, Liu D T, Zhao J F. Stability of molten pool and microstructure evolution of Ti-6Al-4V during laser powder bed fusion with a flat-top beam. Additive Manufacturing, 2023, 75: 103756

[34] Liu B Q, Fang G, Lei L P, Yan X C. Predicting the porosity defects in selective laser melting (SLM) by molten pool geometry. International Journal of Mechanical Sciences, 2022, 228: 107478

[35] Zhang B, Li Y T, Bai Q. Defect formation mechanisms in selective laser melting: a review. Chinese Journal of Mechanical Engineering, 2017, 30(3): 515–527

[36] Karlsson D, Marshal A, Johansson F, Schuisky M, Sahlberg M, Schneider J M, Jansson U. Elemental segregation in an AlCoCrFeNi high-entropy alloy—a comparison between selective laser melting and induction melting. Journal of Alloys and Compounds, 2019, 784: 195–203

[37] Li J J, Zuo D W. Laser polishing of additive manufactured Ti6Al4V alloy: a review. Optical Engineering, 2021, 60(2): 020901

[38] Wang X Y, Li M, Wen Z X. The effect of the cooling rates on the microstructure and high-temperature mechanical properties of a nickel-based single crystal superalloy. Materials, 2020, 13(19): 4256

[39] Panda J P, Arya P, Guruvidyathri K, Ravikirana B S. Studies on kinetics of BCC to FCC phase transformation in AlCoCrFeNi equiatomic high entropy alloy. Metallurgical and Materials Transactions A, 2021, 52(5): 1679–1688

[40] Hecht U, Gein S, Stryzhyboroda O, Eshed E, Osovski S. The BCC-FCC phase transformation pathways and crystal orientation relationships in dual phase materials from Al-(Co)-Cr-Fe-Ni alloys. Frontiers in Materials, 2020, 7: 287

[41] Li J X, Yamanaka K, Chiba A. Significant lattice-distortion effect on compressive deformation in Mo-added CoCrFeNi-based high-entropy alloys. Materials Science and Engineering: A, 2022, 830: 142295

[42] Lan L W, Wang W X, Cui Z Q, Hao X H, Qiu D. Anisotropy study of the microstructure and properties of AlCoCrFeNi_2.1 eutectic high entropy alloy additively manufactured by selective laser melting. Journal of Materials Science and Technology, 2022, 129: 228–239

[43] Gwalani B, Soni V, Lee M, Mantri S A, Ren Y, Banerjee R. Optimizing the coupled effects of Hall–Petch and precipitation strengthening in a Al_0.3CoCrFeNi high entropy alloy. Materials & Design, 2017, 121: 254–260

[44] Liu W H, Wu Y, He J Y, Nieh T G, Lu Z P. Grain growth and the Hall–Petch relationship in a high-entropy FeCrNiCoMn alloy. Scripta Materialia, 2013, 68(7): 526–529

[45] GaoM C, Yeh J W, LiawP K, ZhangY. High-Entropy Alloys: Fundamentals and Applications. Cham: Springer, 2016

[46] Xiong T, Yang W F, Zheng S J, Liu Z R, Lu Y P, Zhang R F, Zhou Y T, Shao X H, Zhang B, Wang J, Yin F X, Liaw P K, Ma X L. Faceted Kurdjumov-Sachs interface-induced slip continuity in the eutectic high-entropy alloy, AlCoCrFeNi_2.1. Journal of Materials Science and Technology, 2021, 65: 216–227

[47] Glaeser W. Friction and wear. IEEE Transactions on Parts, Hybrids, and Packaging, 1971, 7(2): 99–105

Acknowledgements

This work was financially supported by the Shenzhen Science and Technology Program, China (Grant No. GJHZ20220913143012022); the School-level Scientific Research Project of Shenzhen Institute of Technology, China (Grant No. 2211017); the Natural Science Foundation of Guangdong Province, China (Grant No. 2023A1515011641); the Key field Research Projects of Foshan City, China (Grant No. 2120001009232); the Guangdong Huazhong University of Science and Technology Industrial Technology Research Institute, China, and Guangdong Provincial Key Laboratory of Manufacturing Equipment Digitization, China (Grant No. 2020B1212060014); the Postdoctoral Science Foundation of China (Grant No. 2022M710503); and the Natural Science Foundation Commission of Chongqing, China (Grant No. CSTB2022NSCQ-BHX0029).

Electronic Supplementary Material

The supplementary material can be found in the online version of this article at https://doi.org/10.1007s/s11465-024-0804-4 and is accessible to authorized users.

Conflict of Interest

The authors declare that they have no conflict of interest.

RIGHTS & PERMISSIONS

2024 Higher Education Press