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Surface topography of the sample after finishing. a Surface roughness Ra peak-valley diagram, b metallographic diagram, c three-dimensional topography diagram
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In this paper, AlSi10Mg alloy powder is selected as the forming powder of Selective laser melting technology, and the AlSi10Mg alloy SLM curved surface sample is constructed by setting the internal and external layering parameters. In view of the relatively rough surface roughness of SLM technology molded parts, this paper selects the magnetic fini...
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Single-crystal sapphire (α-Al2O3) is an important material and widely used in many advanced fields. The semi-fixed abrasive grain processing method based on solid-phase reaction theory is a prominent processing method for achieving ultra-precision damage-free surfaces. In order to develop the proposed method for polishing sapphire, the basic charac...
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... The results show that magnetic abrasive finishing is a highly effective method for eliminating surface defects, resulting in a significant reduction in surface roughness from 0.75 to 0.08 μm. Cui et al. [20] and others polished the curved surface of an AlSi10Mg sample with magnetic abrasive finishing. They explored the optimal combination of processing parameters through orthogonal experiments. ...
In order to improve the surface roughness of the spherical internal cavity of the special-shaped waveguide which was formed by selective laser melting (SLM) and explore the influence of the main processing parameters of magnetic ball-assisted magnetic abrasive finishing (MAF) on the finishing quality, the structure of the waveguide was analyzed, and a profiling AlSi10Mg test sample based on the structure of waveguide was developed; the self-developed magnetic ball-assisted magnetic abrasive finishing device was used to carry out single-factor experiments on the processing time, the size of magnetic abrasive particles (MAPs), the workpiece rotation speed, and the processing clearance at five levels each. The surface roughness reduction rate was selected as the evaluation index to analyze the influence law of each processing factor on the surface roughness reduction rate and surface morphology which was detected by laser confocal. Then the single-factor experiments were carried out to reveal the evolution of surface morphology in MAF for the spherical internal cavity of the special-shaped waveguide formed by SLM. The results show that the surface roughness reduction rate of sample first increases and then decreases with the increase of processing time, workpiece rotation speed and size of MAPs, and significantly decreases with the increase of processing clearance. Through analysis results of the internal surface of the spherical cavity detected by the laser confocal, the surface roughness of the spherical internal cavity was reduced to 0.694 μm with a reduction rate of 93.94% when the processing time is 20 min, the workpiece rotation speed is 500 r/min, the MAP size is 750 μm, the processing clearance is 1 mm. A large number of unfused powder protrusions attached to the surface were effectively removed, and the surface morphology was greatly improved. The surface quality of spherical internal cavity of irregular waveguide can be significantly improved, and the surface roughness can be effectively reduced by magnetic Ball-assisted magnetic abrasive finishing with appropriate processing parameters.
... They found that magnetic field concentration in the slot increased forces around it and got a better surface finish than [149] Grey relational analysis (GRA) [150] without slot in less time (Refer figures 13(a) and (b)). Cui et al [155] performed numerical analysis of MAF on curved surfaces. They analyzed the effect of slot angle on magnetic field strength and observed that magnetic field strength increases with a decrease in edge angle. ...
Many engineering applications require components with a good surface finish. It is difficult to get the surface finish in the micro/nano level range with conventional finishing processes for materials such as super alloys, composites, and ceramics. Magnetic abrasive finishing (MAF) is one of the processes for achieving superior surface finish. However, the processes efficiency is affected by its operational variables. Even a slight change in a processing parameter may lead to dimensional inaccuracies and poor surface quality of the workpiece. In this paper, recent trends in the magnetic abrasive finishing process are presented along with a critical review. The review includes MAF principles, tools, hybridization, modeling, and simulation of the process. Apart from plane MAF, the principle of MAF for cylindrical workpieces, the mechanism of material removal and the effect of different types of abrasives are also discussed. Various machine tools used for MAF of plane and cylindrical workpieces for external and internal surfaces are also discussed. In hybridization, different processes combined with MAF, like ultrasonic-assisted MAF, chemo-assisted MAF, and electrochemical-assisted MAF, etc., are discussed to increase material removal rate and obtain surface finish at the micro/nano level. The paper also covers mathematical and statistical modeling, simulation, and optimization techniques to predict and optimize the set of input process parameters. Lastly, challenges and conclusions of the MAF process are presented.
... Zhang et al. [15] proposed using the MAF process as a flexible finishing technique to polish the samples generated by the selective laser melted (SLM) process with different slope angles and studied the MAF process effect on the microhardness of the sample surfaces. Teng et al. [16] studied the microhardness as a response factor of the MAF process after machining the workpieces by selective laser melted (SLM) process with varying one parameter (abrasive type). Mousa [17] studied the improvement of the hardness of stainless steel plate 321 by the MAF process with five input parameters (groove number, voltage, speed, time, and powder volume). ...
... Using the MAF process with smaller particles, surface roughness of less than 100 nm was easily achieved in the different build directions, with the initial surface roughness ranging from 4-10 µm. The study carried out by Cui et al. [81] revealed that the MAF process could not significantly influence or affect the hardness of the aluminum alloy part produced by SLM, even though it could greatly enhance the surface morphology while concurrently making the SLM surface hydrophobic. ...
... AlSi10Mg: %ΔR a <98 [79] ; %ΔR a <91 [80] ; %ΔR a <87 [81] ; -Inconel 718: %ΔR a <85 [66] ; %ΔR a <95 [77] ; ...
... Ferrous alloys Al alloys Ti alloys Ni alloys AFM X 2 CrNiMo 17 [19] : R a , MR 18Ni300: R a , [20,41,47] S a , [21,35,36] RS, [21,36,41] MR, [33,34,47] FL [36] SS316L: R a [131] AlSi10Mg [22] : S a , RS AlSi 7 Mg 0.6 : R a [42] Ti-6Al-4 V: R a [42,43] Inconel 718 [25] : R a Inconel 625 [26] : R a A-FBM -AlSi10Mg: R a , [54] WL, [54] S a/z [57,58] Ti-6Al-4 V [55] : R a , WL, YS, FL -MAF SS 316 L: S a , [75,76] R a , [64,65,73,74,76] MR, [64,65,[73][74][75][76] RS, [64,74,75] H [65,74] AlSi10Mg: R a , [79][80][81] MR, [81] H [79,80] -Inconel 718: MR, [66,77] R a , [66,77] RS, [66,77] YS, [77] H [66,77] BF SS 316 L: R a , [95,122] S a , [122] MR [95] -Ti-6Al-4 V: R a , [91,93,94] MR, [93] UTS, [91] YS, [91,94] EL, [91,94] Inconel 718: R a , [93] S a , [118] H, [118,121] W, [118] RS [118,121] VBF SS316L [123] : R a , H 18Ni300 [128] : R a AlSi10Mg [98] : S a , MR Ti-6Al-4 V [129] : R a , H, RS, FL -DF SS316L [123] : R a , H [123] -Ti-6Al-4 V: R a , [96,97] H, [97] CoF, [97] WR [97] -UCAF ---Inconel 625: R a , [101,102,107,108] MR, [102] H [102] HCAF -AlSi10Mg: R a/z , [110,111] MR, [114] H, [114,115] CoF, [114] ER, [111,115] ThL, [111] RS [115] -Inconel 625 [116] : R a/z , S a/z , Sdr (8) New additive manufacturing techniques are emerging in the market, showcasing distinctive surface textures that set them apart from conventional methods. These novel approaches introduce complex surface morphologies due to processes like sintering/melting and layerby-layer deposition. ...
Additive manufacturing has brought revolutionary changes in manufacturing sector by allowing the production of intricate components that were once unattainable using traditional methods. However, poor surface integrity of these components necessitates further post-processing to improve their surface quality and functionality. Thermal and chemical energy-based post-processes, result in a contaminated/modified surface metallurgy on finished surfaces, which are highly discouraged in industries such as aerospace, automobile, biomedical etc. Mechanical energy-based post-processes, like finish machining, burnishing, etc., are limited due to their constraints related to the geometrical shape of the component. In contrast, abrasive media-assisted post-processes improve surface integrity by removing the material as tiny chips and do not result any metallurgical changes. Therefore, it is worth exploring the various post-processing techniques under this category. A detailed description and work carried out under each process of this group are reported. Research gaps are highlighted, and opportunities to address them are discussed briefly.
... Jiong Zhang et al. [11] investigated MAF of SLM-printed samples and observed the removal of partially bonded surface particles, low balling defects, and low surface roughness which decreased by 76%. Xiao Teng et al. [12] carried out a study on MAF of SLM-built AlSi10Mg Al alloy samples. MAF was applied post grinding process in which the surface roughness after grinding process decreased to 0.6 µm from 4.5 µm and then, it reduced to 0.155 µm with MAF. ...
Surface finish significantly affects assembled component’s functional aspects like fatigue life, corrosion resistance, wear, etc. Ultrasonic-Assisted Magnetic Abrasive Finishing (UAMAF) is an integration of ultrasonic vibrations to Magnetic Abrasive Finishing (MAF) process to finish surfaces up to nanometre level in a short time. Current work focuses on fabricating UAMAF setup on vertical milling machine and finishing Selective Laser Melting (SLM) built samples made of AlSi12Mg alloy using loose Silicon carbide abrasive particles. Finishing was performed on As-built, surface ground samples in which surface roughness reduction percentage was 97.93% in Heat Treated (HT) samples combined with grinding process and UAMAF, 96.57% in Non Heat Treated (NHT) samples combined with grinding process and UAMAF. There was no change in elemental composition even after employing UAMAF. Microstructure showed increase in abrasives impacted on the surface, achieving surface finish in lower time. Magnitude of residual stresses induced during SLM and grinding process reduced drastically by about 112.13%, 149.90% respectively by UAMAF in NHT, HT samples and nature of stresses were altered from tensile to compressive. Overall results revealed that UAMAF is more effective when applied to SLM-printed heat-treated AlSi12Mg samples than cast, non-heat-treated samples. The friable nature of Silicon carbide abrasives influences finishing time which in turn affects surface finish in UAMAF.
... As the metal industry has evolved, progress has also been made in characterizing the mechanical properties and resistance of metal materials. Advanced testing techniques such as scanning electron microscopy (SEM), AFM microscopy, and non-destructive testing enable the precise examination of material structures and strength, which is crucial for ensuring the quality of manufactured products [9][10][11][12][13]. ...
Welded resistance slotted screens, also known as slotted screens, are a special type of screen primarily used for the filtration and separation of liquids and dust. They are characterized by slots with parallel geometry and precisely defined sizes. The quality of the side surfaces and edges of welded wires determines the durability of the slotted screens made from them. This article presents the results of tests for four types of wires: two types of working profile wires made from austenitic-ferritic steel (duplex) and two types of supporting cross wires made from ferritic steel. The wire surfaces were characterized using a profilometer and atomic force microscopy. Basic roughness parameters Ra, Rz, and SAD (surface area difference) were determined. Surface observations of the working profiles were conducted using scanning electron microscopy. These studies allowed for the characterization of the working wire surfaces used in the production of slotted screens. At work, the results of surface roughness were analyzed based on three measurement methods for wires used in the production of welded slot screens. These results allowed for the identification of the most reliable method for characterizing the surface condition of such products.
This study investigates the finishing characteristics of internal channels with different cross-sectional geometries using free abrasive grains and evaluates the cooling performance of these channels before and after finishing. Three types of channels with circular, triangular, and hexagram cross-sections were designed and fabricated using laser powder bed fusion (L-PBF). A fluid flow in the channel was evaluated using computational fluid dynamics simulations, and the finishing characteristics and cooling performances of the channels were experimentally investigated. The results indicated that the use of free abrasive grains enabled the improvement in the surface quality as well as the cooling performance of the channel. The cross-section of the channel affected the fluid flow in the channel and finishing progress. The initial surface roughness varied with the cross-section of the channel owing to the limitations of L-PBF, and the triangular section had a relatively uniform surface quality throughout the channel compared with the other cross-sections. The cooling time decreased with the surface area of the channel. To obtain the uniform surface quality, the application of a suitable cross-section is needed for the finishing process. The outcomes of this study demonstrate that a triangular-section channel is suitable for improving both surface quality and cooling performance.
Remanufacturing has emerged as an effective strategy to promote sustainability, reduce waste, and enhance resource efficiency in modern manufacturing processes. However, traditional remanufacturing methods have limitations in producing complex geometries and restoring parts to their original condition, leading to reduced performance and durability. Metal additive manufacturing (AM) methods have shown significant potential in overcoming these limitations and enhancing the quality and reliability of remanufactured parts. Metal AM enables the production of replacement parts with high geometrical complexity and tight tolerances. On the other hand, surface treatment techniques, such as polishing and coating, can improve the surface properties of additively manufactured parts. Recent advancements in metal AM have led to significant progress in manufacturing technologies, including the development of hybrid methods combining metal AM with a surface treatment to achieve superior surface finish and accuracy while reducing production time and cost. Despite progress, challenges such as the need for cost-effective and scalable processing methods, the development of new materials, and the optimization of process parameters for specific applications still need to be addressed. Moreover, although surface modification techniques suitable for metal components fabricated through additive manufacturing can be employed for remanufactured parts, their adoption needs to be improved and necessitates additional advancement. This paper provides an overview of recent progress in manufacturing and remanufacturing technologies using metal additive manufacturing processes and surface treatments, highlighting their potential to significantly improve the quality and reliability of remanufactured parts. The paper concludes with a discussion of the future prospects of this field and the need for continued research and development to fully realize the potential of remanufacturing technologies.
Since the advent of additive manufacturing (AM) (also called 3D-printing), substantial progress has been achieved in technological advances in the processes and micro/macro characteristics of the components. However, this rapidly evolving field is faced with some barriers to industrial adoption, especially in the case of metals processing. Poor surface quality and surface topography imperfections, which are inherent in metal AM, are among the main drawbacks hindering AM broad industrial adoption. This issue cannot be addressed only by AM process optimization due to the intrinsic complexity of the process. Therefore, effective surface post-treatment methods are required to enhance the surface quality of the final parts for both external and hard-to-reach internal surfaces. Considering the importance and urgent need for surface modification of AM metals, this review aims to provide a broad overview of the existing research endeavors as well as gaps and opportunities in the surface enhancement of AM metals, with a focus on solution-based approaches to improve surface roughness of complex metal 3D-printed parts with intricate surfaces and evaluate the effect of these approaches on the functional properties for end-use applications. Assessing the effectiveness of the surface modification techniques, the present paper further provides the research needs to fulfill the performance-impacting knowledge gap for AM industrial adoption and further expansion of surface treatment methodologies for improved surface finish of complex metal printed parts.
