?? Enhancing Ti6Al4V Titanium Alloy Surface Quality: A Comparative Study of E-PBF and L-PBF Laser Polishing Techniques ??

Researchers from the University of In the realm of metal additive manufacturing, surface quality plays a crucial role in determining the material's performance. To improve this quality, laser polishing techniques have been applied to Ti6Al4V titanium alloy samples manufactured via Electron Beam Powder Bed Fusion (E-PBF) and?Laser Powder Bed Fusion?(L-PBF). Researchers from the University of Naples Federico II in Italy and Dublin City University in Ireland have conducted meticulously designed experiments to evaluate the effectiveness of these laser polishing techniques.

???Experimental Design and Methods???

Researchers first prepared Ti6Al4V alloy samples using E-PBF?and L-PBF?technologies and then performed laser polishing under different conditions.

The Box-Behnken Design (BBD) was employed to optimize laser polishing parameters, including laser power, scanning speed, and number of passes.

Each sample underwent detailed surface analysis and statistical evaluation.

???E-PBF?vs. L-PBF?Process Parameters???

E-PBF?Parameters:

Voltage: 60kV

Scan Distance: 55μm

Layer Thickness: 90μm

Build Platform Temperature: 730°C

L-PBF?Parameters:

Laser Power: 350W

Scan Distance: 55μm

Layer Thickness: 30μm

Build Platform Preheat: 400°C

Scan Strategy: Raster type, 67° layer rotation

???Results Analysis???

Laser polishing significantly improved the surface quality of both samples, especially for the E-PBF?sample, which saw an average surface roughness reduction of 68%.

The initial surface roughness of E-PBF?samples was 54.3±4.1μm, reduced to an average Sa value of 17.3±3.3μm post-polishing.

L-PBF?samples showed an initial surface roughness of 10.2±1.1μm, reduced to an average Sa value of 5.4±0.5μm after polishing.

???Statistical Analysis???

For E-PBF?samples, the correlation between polishing parameters and surface roughness was weak (adjusted R2 of 0.17), indicating high sensitivity to surface irregularities.

For L-PBF?samples, a quadratic model best described the data (adjusted R2 of 0.7), demonstrating significant effects of laser power, translation speed interaction, and time autocorrelation factors on surface roughness.

???Microstructure and Chemical Composition???

E-PBF?samples exhibited a microstructure change post-polishing from martensitic to fine-woven and basket-weave structures, with no change in chemical composition or Vickers microhardness.PBF?samples exhibited a microstructure change post-polishing from martensitic to fine-woven and basket-weave structures, with no change in chemical composition.

???Discussion???

This study's findings are significant for the additive manufacturing field. Laser polishing not only improves surface quality but also allows for precise control of surface roughness through optimized process parameters.

Despite some microstructure modifications, laser polishing did not significantly alter chemical composition or hardness, critical for maintaining overall material performance.

???Conclusion???

Laser polishing technology shows immense potential in improving the surface quality of additively manufactured titanium alloy samples.

It significantly reduces surface roughness and can refine the microstructure without compromising other material properties.

As additive manufacturing technology continues to evolve, laser polishing is poised to become a critical step in enhancing product quality, supporting the production of higher-performance metal components. Future research will delve deeper into the underlying mechanisms of laser treatment on material properties and explore its applications across a broader range of materials and scenarios. ??

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