15-Dec-21
Post-processing of AM Parts
(Integration of techniques)
Radha Raman Mishra, Ph. D.
Course Instructor & Assistant Professor
Department of Mechanical Engineering
Introduction
• Post processing: final step of the manufacturing process which offers –
smoothing and
strengthening
• Despite many advantages of AM over traditional manufacturing, it is still imperfect.
• AM parts can still have poor surface finishes, and the production method can affect
the mechanical properties of the component.
• The main objective of post-processing is to eliminate potentially dangerous defects
• Post processing methods can include –
heat treatment (to reduce the stress on components)
separating the components from support structure
surface finishing (CNC machining, blasting and polishing)
• The post processing of AM parts can be just as vital as the fabrication itself. 2
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Issues in AM
Surface roughness achieved in different AM processes
• Demand for better materials.
• Existing CAD systems.
• Data management (Size of STL file)
• Low-volume production
• Financial overheads
• Surface Quality of Products
Kumbhar, N. N., & Mulay, A. V. (2018). Post processing methods used to improve surface finish of products which are manufactured by additive manufacturing technologies: a
review. Journal of The Institution of Engineers (India): Series C, 99(4), 481-487. 3
Issues in AM
To minimize the Stair casing
a CAD Model b Slicing c Actual output d Stair casing effect effect, the possible approaches
are –
• Control over parameters
part orientation
layer thickness and
orientation of material
deposition
• Post-processing techniques
Effect of reducing layer thickness
Kumbhar, N. N., & Mulay, A. V. (2018). Post processing methods used to improve surface finish of products which are manufactured by additive manufacturing technologies: a
review. Journal of The Institution of Engineers (India): Series C, 99(4), 481-487. 4
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Post-processing methods
Classification of Post-processing methods
Different raw materials
Nature of the process
Kumbhar, N. N., & Mulay, A. V. (2018). Post processing methods used to improve surface finish of products which are manufactured by additive manufacturing technologies: a
review. Journal of The Institution of Engineers (India): Series C, 99(4), 481-487. 6
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Thermal Post-Processing
• Hot isostatic pressing
• Heat treatment
Solution HT
T6 HT
Optical micrographs presenting defects. (a) Electron beam melting
(EBM) part (b) after the hot isostatic pressing (HIP) treatment.
Schematic diagram of SEM micrographs. (a,b) as-built. (c,d) HIP. (e,f) HIP + HT
Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 7
Laser Peening
Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 8
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Laser Polishing
• During laser polishing, morphology apexes can
reach the melting temperature rapidly when the
energy source irradiates the material surface.
• The liquid material redistributes to the same
level after molten-pool formation because of the
effect of gravity and surface tension.
• Once the laser beam stops scanning the surface,
the temperature of the heat-affected zone (HAZ)
drops rapidly, resulting in the solidification of the
molten pool, and the surface roughness reduces
accordingly
(a) Overview of the substrate and laser-polished region. (b)
Microstructure of the laser-polished region. (c) Microstructure of the
substrate. (d) XRD profiles.
Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 9
Machining and Abrasive Finishing
SLM-ed AlSiMg0.75
Difference in surface finish for
an untreated and CNC
machined part
(a) conventional diamond turning (b) ultrasonic elliptical vibration-assisted machining
Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 10
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Machining and Abrasive Finishing
Micro-blasting of SLM-ed tubular lattice structure. (a) setup. (b) lattice structure before micro-blasting. (c) after blasting
Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 11
Impact of post-processing
True stress strain plots of 3D printed samples with different printing speeds: (a) 88 μm (fast) and (b) 110 μm (slow) respectively.
In each plot, the three curves correspond to three different treatments including 3D printing (blue), 3D printing and 900 °C heat
treatment (red) and 3D printing, 900 °C hot forging and 900 °C heat treatment (yellow)
Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 12
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Impact of post-processing
Mean values of conventional Vickers hardness of fast (blue) and slow (yellow) 3D printed samples for three different treatments, namely direct 3D
printing, 900 °C heat treating after printing, and 900 °C forging (900°C H) and 900 °C heat treatment after printing (900°C F+900°C H).
Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 13
Thank you
All the best for Comprehensive Examination
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