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Surface Polishing of Laser Powder Bed Fused Inconel 625 Surfaces Using Multi-jet Hydrodynamic Cavitation Abrasive Finishing: An Emerging Class of Cleaner Surface Enhancement Process

Polishing the laser powder bed fused (L-PBF) components and achieving uniform roughness is exceptionally challenging. Moreover, retaining the dimensional integrity of intricate features during polishing is difficult. This research aims to overcome these issues by developing a novel multi-jet hydrody...

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Published in:International journal of precision engineering and manufacturing-green technology 2023-05, Vol.10 (3), p.637-657
Main Authors: Nagalingam, Arun Prasanth, Toh, Boon Loong, Yeo, Swee Hock
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Language:English
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description Polishing the laser powder bed fused (L-PBF) components and achieving uniform roughness is exceptionally challenging. Moreover, retaining the dimensional integrity of intricate features during polishing is difficult. This research aims to overcome these issues by developing a novel multi-jet hydrodynamic cavitation abrasive finishing (MJ-HCAF) approach for polishing the complex L-PBF components. The technique proposed in this article uses cavitation principles as a constructive tool for polishing hard-to-machine materials within 10 min. A new industrial-scale apparatus was developed to realize the proposed concept. L-PBF Inconel 625 surfaces were polished to demonstrate the MJ-HCAF technique's effectiveness. The MJ-HCAF technique resulted in up to ~ 85% improvement in surface texture quality (final Sa ≤ 0.5 µm; Sz ≤ 10 µm). Moreover, the final appearance was controlled to glossy or matt polish to suit aerospace aesthetic requirements. The proposed technique uses water as the primary working fluid with abrasives ≤ of 1.0% to generate a polished surface (conventional abrasive-based methods use 60–80%)—indicating an emerging class of cleaner manufacturing process. The Product Sustainability Index (PSI) for a sustainable approach showed that cavitation-assisted abrasive polishing mode has the highest PSI score of 7.88. The key factors leading to its high score are its synergistic effects, low-cost water operation, and extremely low abrasive usage.
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subjects Abrasive cleaning
Abrasive finishing
Abrasives
Cavitation
Cost control
Efficiency
Lasers
Manufacturing
Manufacturing industry
Metal fatigue
Nickel base alloys
Polishes
Polishing
Powder beds
Superalloys
Surface layers
Synergistic effect
Viscoelasticity
Working fluids
title Surface Polishing of Laser Powder Bed Fused Inconel 625 Surfaces Using Multi-jet Hydrodynamic Cavitation Abrasive Finishing: An Emerging Class of Cleaner Surface Enhancement Process
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