Synergistic Effects of Post-Processing on PBF Metal Components Mechanical Performance

Conference Abstract: Metal additive manufacturing (AM) has revolutionized the production of metal components by allowing multiple components to consolidate in one build, reducing lead times and cutting costs. However, the rigorous requirements and standards these components must meet, especially in safety-critical applications, still need to be completed. Fatigue performance and corrosion resistance are crucial and common limitations for AM applications, given their close association with surface texture and common surface-related defects (SRD) in AM builds.
In several critical sectors, such as medical, aerospace, and space exploration, SRD removal is essential before utilizing AM components. Similarly, instances of porosity near the surface, often linked to contour/hatching interphase regions, have been observed in AM components. Addressing these SRD and porosity issues is essential for meeting industry standards, forcing suitable surface finishing and heat treatment operations to meet the required standards.
While surface finishing processes can mitigate many SRDs, they often expose near-surface porosity, resulting in a heavily pitted surface. To enhance the mechanical performance of metal-AM components, it becomes necessary to remediate this internal porosity through techniques like hot isostatic pressing (HIP). This presentation showcases the synergistic effects of surface-associated contour printing parameters, HIP, and surface finishing on metal AM components, exploring their implications for mechanical and corrosion resistance performance.
The research will focus on AlF357, Scalmalloy, IN-625, IN-718, and Ti6Al4V alloys. The presentation will delve into the effects of these factors on the metallographic structures, tensile strength, fatigue performance, and corrosion resistance, discussing how the developed technology targets various SRD types and overcomes challenges, ultimately producing surface-finished components that meet the industry's standards.