Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy
The Selective laser melting (SLM) technology of recent years allows for building complex-shaped parts with difficult-to-cut materials such as Ti6Al4V alloy. Nevertheless, the surface integrity after SLM is characterized by surface roughness and defects in the microstructure. The use of additional fi...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-08-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/16/15/5476 |
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| author | Dorota Oniszczuk-Świercz Rafał Świercz |
| author_facet | Dorota Oniszczuk-Świercz Rafał Świercz |
| author_sort | Dorota Oniszczuk-Świercz |
| collection | DOAJ |
| description | The Selective laser melting (SLM) technology of recent years allows for building complex-shaped parts with difficult-to-cut materials such as Ti6Al4V alloy. Nevertheless, the surface integrity after SLM is characterized by surface roughness and defects in the microstructure. The use of additional finishing technology, such as machining, laser polishing, or mechanical polishing, is used to achieve desired surface properties. In this study, improving SLM Ti6Al4V alloy surface integrity using wire electrical discharge machining (WEDM) is proposed. The influence of finishing WEDM cuts and the discharge energy on the surface roughness parameters Sa, Svk, Spk, and Sk and the composition of the recast layer were investigated. The proposed finishing technology allows for significant improvement of the surface roughness by up to 88% (from Sa = 6.74 µm to Sa = 0.8 µm). Furthermore, the SEM analyses of surface morphology indicate improving surface integrity properties by removing the balling effect, unmelted particles, and the presence of microcracks. EDS analysis of the recast layer indicated a significant influence of discharge energy and the polarization of the electrode on its composition and thickness. Depending on the used discharge energy and the number of finishing cuts, changes in the composition of the material in the range of 2 to 10 µm were observed. |
| first_indexed | 2024-03-11T00:22:49Z |
| format | Article |
| id | doaj.art-c54ae7f7f28848d09583484e4d129269 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-11T00:22:49Z |
| publishDate | 2023-08-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-c54ae7f7f28848d09583484e4d1292692023-11-18T23:13:50ZengMDPI AGMaterials1996-19442023-08-011615547610.3390/ma16155476Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V AlloyDorota Oniszczuk-Świercz0Rafał Świercz1Institute of Manufacturing Technology, Faculty of Mechanical and Industrial Technology, Warsaw University of Technology, Narbutta 85, 02-524 Warsaw, PolandInstitute of Manufacturing Technology, Faculty of Mechanical and Industrial Technology, Warsaw University of Technology, Narbutta 85, 02-524 Warsaw, PolandThe Selective laser melting (SLM) technology of recent years allows for building complex-shaped parts with difficult-to-cut materials such as Ti6Al4V alloy. Nevertheless, the surface integrity after SLM is characterized by surface roughness and defects in the microstructure. The use of additional finishing technology, such as machining, laser polishing, or mechanical polishing, is used to achieve desired surface properties. In this study, improving SLM Ti6Al4V alloy surface integrity using wire electrical discharge machining (WEDM) is proposed. The influence of finishing WEDM cuts and the discharge energy on the surface roughness parameters Sa, Svk, Spk, and Sk and the composition of the recast layer were investigated. The proposed finishing technology allows for significant improvement of the surface roughness by up to 88% (from Sa = 6.74 µm to Sa = 0.8 µm). Furthermore, the SEM analyses of surface morphology indicate improving surface integrity properties by removing the balling effect, unmelted particles, and the presence of microcracks. EDS analysis of the recast layer indicated a significant influence of discharge energy and the polarization of the electrode on its composition and thickness. Depending on the used discharge energy and the number of finishing cuts, changes in the composition of the material in the range of 2 to 10 µm were observed.https://www.mdpi.com/1996-1944/16/15/5476Ti6Al4Vfinishing surfaceWEDMadditive manufacturingSLM |
| spellingShingle | Dorota Oniszczuk-Świercz Rafał Świercz Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy Materials Ti6Al4V finishing surface WEDM additive manufacturing SLM |
| title | Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy |
| title_full | Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy |
| title_fullStr | Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy |
| title_full_unstemmed | Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy |
| title_short | Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy |
| title_sort | effects of wire electrical discharge finishing cuts on the surface integrity of additively manufactured ti6al4v alloy |
| topic | Ti6Al4V finishing surface WEDM additive manufacturing SLM |
| url | https://www.mdpi.com/1996-1944/16/15/5476 |
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