This text defines and covers different themes of post-processing techniques based on mechanical, chemical/electrochemical, and thermal energy. It will serve as an ideal reference text for senior undergraduate and graduate students in diverse engineering fields including manufacturing, industrial, aerospace, and mechanical.
This book
covers the fundamentals and advancements in the post-processing techniques for additive manufacturing;
explores methods/techniques for post-processing different types of materials used in additive manufacturing processes;
gives insight into the process selection criteria for post-processing of additive manufactured products made from different types of materials;
discusses hybrid processes used for post-processing of additive manufacturing parts; and
highlights post-processing techniques for properties enhancement.
The primary aim of the book is to give the readers a well-informed layout of the different post-processing techniques that range from employing mechanical energy to chemical, electrochemical, and thermal energy to perform the intended task.
Author(s): Zafar Alam, Faiz Iqbal, Dilshad Ahmad Khan
Publisher: CRC Press
Year: 2023
Language: English
Pages: 290
City: Boca Raton
Cover
Half Title
Title Page
Copyright Page
Table of Contents
Preface
About the editors
List of contributors
Chapter 1: Additive manufacturing and post-processing: An introduction
1.1 Introduction
1.1.1 Working principle
1.1.2 Procedure of AM
1.2 AM cataloguing and feed materials
1.3 Applications
1.4 Need for post-processing of additively manufactured parts
1.4.1 Fused deposition modelling
1.4.1.1 Defects occurring in FDM parts
1.4.2 Powder bed fusion
1.4.2.1 Defects occurring in PBF parts
1.4.3 Laminated object manufacturing
1.4.3.1 Defects occurring in LOM manufactured parts
1.4.4 Wire arc additive manufacturing
1.4.4.1 Need for post-processing of WAAM manufactured parts
1.5 Post-processing techniques
1.5.1 Mechanical post-processing techniques
1.5.2 Chemical and electrochemical post-processing techniques
1.5.2.1 Chemical polishing
1.5.2.2 Electrochemical polishing
1.5.2.3 Electroplating
1.5.2.4 Chemical etching
1.5.2.5 Vapour smoothing
1.5.2.6 Acetone dipping
1.5.3 Thermal post-processing techniques
1.5.4 Hybrid post-processing techniques
1.5.5 Post-processing techniques for properties enhancement
References
Chapter 2: Mechanical post-processing techniques for metal additive manufacturing
2.1 Introduction
2.2 Mechanical techniques for post-processing of metal AM parts
2.2.1 Abrasive flow machining
2.2.2 Vibratory finishing
2.2.3 Shot peening
2.2.4 Blasting
2.2.5 Ultrasonic abrasion finishing
2.2.6 Hot cutter machining
2.2.7 Micromachining
2.2.8 Magnetic field-assisted finishing
2.3 Conclusion
References
Chapter 3: Vibratory surface finishing of additive components prepared from the laser powder bed fusion process
3.1 Introduction
3.2 Existing mechanical post-processing methods and their limitations
3.3 Mass finishing techniques
3.4 Influence of abrasive media type on the workpiece surface
3.5 Influence of media rotation on the workpiece surface
3.6 Influence of the process duration on the workpiece surface
3.7 Effect of lubricants on the workpiece surface
3.8 Numerical studies
3.9 Future possibilities and summary
References
Chapter 4: Ball burnishing of additively manufactured parts
4.1 Introduction
4.2 Burnishing process
4.3 Burnishing of additively manufactured parts
4.3.1 Ball burnishing (BB)
4.3.1.1 Analytical models of BB
4.3.1.1.1 Normal and tangential force
4.3.1.1.2 Slab method analysis
4.3.1.1.3 Consideration of the time perspective
4.3.1.2 Ball burnishing of AM parts
4.3.2 Ultrasonic vibration-assisted ball burnishing (UVABB)
4.3.2.1 Analytical models of UVABB
4.3.2.1.1 Static force
4.3.2.1.2 Dynamic force
4.3.2.2 Ultrasonic vibration-assisted ball burnishing (UVBB) of AM parts
4.4 Conclusion
References
Chapter 5: A critical review of mechanical-based post-processing techniques for additively manufactured parts
5.1 Introduction
5.2 Classification of AM technologies based on usage of standard and classic methods
5.3 Need for Post-processing of AM parts
5.4 Classification of post-processing techniques to enhanced the surface quality of the AM part
5.5 Mechanical-based surface quality improvement methods
5.5.1 Manual sanding
5.5.2 Abrasive flow machining
5.5.3 CNC staircase machining and abrasive milling
5.5.4 Sandblasting
5.5.5 Vibratory bowl finishing
5.5.6 Barrel tumbling
5.5.7 Hot cutter machining
5.5.8 Ball burnishing
5.5.9 Magnetic based finishing
5.6 Conclusions and future direction
5.6.1 Challenges and future direction
References
Chapter 6: Chemical post-processing for fused deposition modelling
6.1 Introduction
6.2 Fused deposition modelling (FDM)/fused filament fabrication (FFF)
6.3 Defectology
6.4 Printing parameters
6.4.1 Temperature
6.4.2 Bed temperature
6.4.3 Chamber temperature
6.4.4 Printing speed
6.4.5 Layer height
6.4.6 Extrusion width
6.4.7 Extrusion multiplier
6.4.8 Nozzle diameter
6.4.9 Raster angle
6.4.10 Cooling rate
6.4.11 Build orientation
6.5 Post-processing techniques
6.6 Chemical post-processing
6.6.1 Manual painting
6.6.2 Electroplating/galvanizing
6.6.3 Solvents dipping/vapour smoothing
6.7 Conclusions
References
Chapter 7: Post welding cold forging and effect on mechanical properties of low-carbon mild steel wire arc additive manufacturing
7.1 Introduction
7.2 Enhancement of properties in WAAM
7.2.1 Post process heat treatment
7.2.2 Interpass cold rolling
7.2.3 Peening and ultrasonic impact treatment
7.2.4 Interpass cooling
7.3 Methodology
7.3.1 Parameters for MIG welding
7.3.2 Specimen preparation
7.3.3 Characterization
7.4 Results and discussion
7.4.1 Tensile test
7.4.2 Hardness test
7.4.3 Microstructure observation
7.4.4 Impact toughness
7.5 Conclusions
Acknowledgement
References
Chapter 8: Severe plastic deformation for fatigue strength of additively manufactured components
8.1 Importance of fatigue
8.2 Why is fatigue strength an issue in additive manufacturing?
8.3 Fatigue life enhancement processes
8.3.1 Shot peening
8.3.2 Hammer peening
8.3.3 Deep cold rolling/burnishing
8.3.4 Laser shock peening
8.3.5 Other SPD techniques
8.3.6 Hot isostatic pressing
8.3.7 Summary of processes
8.4 Conclusions
References
Chapter 9: Comparison of effects of ultrasonic and shot peening treatments on surface properties of L-PBF-manufactured superalloy subjected to HIP combined with heat treatments
9.1 Introduction
9.2 Material and methods
9.2.1 Laser powder bed fusion details
9.2.2 Heat post-processing
9.2.2.1 Hot isostatic pressing
9.2.2.2 Heat post-processing
9.2.3 Mechanical surface post-processing
9.2.3.1 Ultrasonic impact peening
9.2.3.2 Shot peening
9.2.4 Material examination methods
9.2.4.1 Microstructural characterization
9.2.4.2 Hardness measurements
9.2.4.3 Topography observation
9.3 Results and discussion
9.3.1 Microstructure examination
9.3.2 Residual stress and hardness
9.3.3 Porosity
9.3.4 Surface texture
9.3.5 Roughness and waviness
9.4 Conclusions
Fundings
References
Chapter 10: Post-processing techniques of additively manufactured Ti-6Al-4V alloy: A complete review on property enhancement
10.1 Introduction
10.2 Chronological evolution of AM technologies for metals
10.2.1 Sheet lamination or laminated object manufacturing (LOM)
10.2.2 Powder bed fusion systems
10.2.3 Powder feed systems or direct energy depositions (DED)
10.2.4 Wire arc additive manufacturing (WAAM)
10.3 Defects in additively manufactured metal components
10.3.1 Formation of porosity
10.3.2 Crack formation
10.3.3 Residual stress problems in AM parts
10.3.4 Build orientation effect on AM parts
10.3.5 Surface roughness problem in AM parts
10.4 Defects and significant challenges occurring specifically in additively manufactured Ti-6Al-4V components
10.5 Post-processing techniques for additively manufactured Ti-6Al-4V components
10.5.1 Heat treatment process
10.5.2 Hot isostatic pressing (HIP) process
10.5.3 Shot peening process
10.5.4 Surface finish methods
10.5.4.1 Polishing
10.5.4.2 Electropolishing
10.5.4.3 Abrasive flow machining
10.5.4.4 Abrasion finishing/grinding
10.5.4.5 Abrasive blasting/bead blasting
10.6 Conclusions
References
Index
