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<p>In recent years, the titanium alloy Ti6Al4V, widely used in aerospace, biomedical, automotive, and energy applications, has gained growing attention in additive manufacturing (AM). Selective laser melting (SLM) enables complex geometries and weight reduction, but the as-built SLMed Ti6Al4V components often suffer from poor surface finish, dimensional inaccuracies, and high residual tensile stresses. These issues – stemming from the layerwise deposition and steep thermal gradients – compromise mechanical performance (e.g., fatigue life) and necessitate subsequent post-processing. This review surveys recent literature on conventional post-machining techniques applied to SLMed Ti6Al4V. It covers turning, milling, and drilling for geometric correction and support removal, as well as grinding and polishing for surface refinement. Collectively, these methods significantly improve surface roughness, dimensional accuracy, and residual stress profiles, thereby enhancing component integrity. The surveyed studies highlight optimization of cutting parameters, tool strategies (including ultrasonic and cryogenic-assisted machining), and combined processes (e.g., machining plus heat treatment) as critical steps in processing SLMed Ti6Al4V. Key challenges remain: the nonuniform microstructure, elevated hardness, and large anisotropic residual stresses of SLMed material lead to higher cutting forces, accelerated tool wear, and unpredictable outcomes. Recent trends point to hybrid additive–subtractive approaches, advanced cooling/lubrication, and predictive modeling to overcome these obstacles. Overall, the review identifies technological advances and research gaps, outlining future directions for efficiently finishing SLMed Ti6Al4V in high-value applications.</p>

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A short review of the post-processing of titanium alloys processed by selective laser melting

  • 期刊论文

  • 发表日期：

    2025年5月27日

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  • Huozan Zhang,
  • Xufeng Tang,
  • Wenjie Guo,
  • Junsheng Gao,
  • Junxi Yu,
  • Xiaoming Yin,
  • Yan Wang,
  • Yinghuai Dong,
  • Zhenwei Jiang,
  • Zhongpeng Zheng

摘要

In recent years, the titanium alloy Ti6Al4V, widely used in aerospace, biomedical, automotive, and energy applications, has gained growing attention in additive manufacturing (AM). Selective laser melting (SLM) enables complex geometries and weight reduction, but the as-built SLMed Ti6Al4V components often suffer from poor surface finish, dimensional inaccuracies, and high residual tensile stresses. These issues – stemming from the layerwise deposition and steep thermal gradients – compromise mechanical performance (e.g., fatigue life) and necessitate subsequent post-processing. This review surveys recent literature on conventional post-machining techniques applied to SLMed Ti6Al4V. It covers turning, milling, and drilling for geometric correction and support removal, as well as grinding and polishing for surface refinement. Collectively, these methods significantly improve surface roughness, dimensional accuracy, and residual stress profiles, thereby enhancing component integrity. The surveyed studies highlight optimization of cutting parameters, tool strategies (including ultrasonic and cryogenic-assisted machining), and combined processes (e.g., machining plus heat treatment) as critical steps in processing SLMed Ti6Al4V. Key challenges remain: the nonuniform microstructure, elevated hardness, and large anisotropic residual stresses of SLMed material lead to higher cutting forces, accelerated tool wear, and unpredictable outcomes. Recent trends point to hybrid additive–subtractive approaches, advanced cooling/lubrication, and predictive modeling to overcome these obstacles. Overall, the review identifies technological advances and research gaps, outlining future directions for efficiently finishing SLMed Ti6Al4V in high-value applications.