Enhancement of Surface Quality of 316L Stainless Steel Parts Produced by Direct Laser Metal Sintering (DLMS) Using Abrasive Flow Machining (AFM) Process
摘要
Additive manufacturing (AM) has become a pivotal production technique in contemporary manufacturing, driven by advancements in modern technology. This approach enables the fabrication of complex components with enhanced functional properties that are often unattainable through conventional methods. Additive manufacturing involves the layer-by-layer deposition of materials guided by three-dimensional (3D) model data, distinguishing it from traditional subtractive and formative manufacturing processes. Moreover, the development of various AM methods and technologies has expanded the range of producible materials, including those that are otherwise incompatible with conventional manufacturing techniques. Direct Laser Metal Sintering (DLMS) is an advanced additive manufacturing technique based on the powder bed fusion process, where a high-powered laser selectively fuses metal powders layer by layer to produce complex 3D components from CAD models. Applicable to a wide range of materials including stainless steels, titanium and aluminum alloys, nickel-based super-alloys, and cobalt-chrome, DLMS enables the production of geometrically complex, high-performance parts with minimal material waste. Its advantages include design flexibility, enhanced mechanical properties, and suitability for functional end-use components. DLMS plays a critical role in aerospace, medical, automotive, and energy sectors, offering integration with Industry 4.0 through digital process control and customization capabilities. However, a notable disadvantage of DLMS is the relatively high surface roughness of the produced parts. This is primarily due to the layer-by-layer fabrication process and partially sintered or adhered powder particles that remain on the surface. The relatively high surface roughness inherent to DLMS-produced components negatively affects fatigue life and induces stress concentrations, thereby limiting their applicability in critical industrial applications. As a result, post-processing such as machining or polishing is often required to achieve the desired surface finish. However, conventional techniques such as machining or polishing are frequently impractical, particularly for components with complex geometries or internal features, or when working with materials that present post-processing challenges. This has highlighted the necessity for more effective and geometry-independent non-conventional surface finishing solutions. In this regard, Abrasive Flow Machining (AFM) offers a promising alternative. AFM is a non-traditional finishing process in which a semi-solid, abrasive-laden media is extruded through the internal channels or surfaces of a component, enabling uniform material removal and significant improvement in surface finish. This study investigated the surface enhancement of 316 L stainless steel parts produced by the DMLS method using the Abrasive Flow Machining (AFM) process, demonstrating the effectiveness of AFM in significantly improving surface roughness.