Direct metal laser sintering (DMLS) is an additive manufacturing process where a laser selectively sinters metal powder particles, fusing them to create a solid part. Post-processing techniques are essential for additive manufacturing (AM) to achieve printed parts’ desired final properties, functionality, and aesthetics. A high-intensity laser beam is used in laser polishing to heat and melt the item’s surface. Because the molten material reflows and hardens, the surface becomes smoother. Surface flaws such as burrs or roughness can be removed selectively using laser polishing without altering the overall dimensions of the part. Cobalt–chromium alloy is used as a substrate for fabricating surgical and dental implants due to its high weight-to-strength, biocompatibility, and toxicity. The study aimed to improve the surface finish of the lateral or side surfaces of an additively manufactured cobalt chrome alloy by changing process parameters such as laser power and scan speed. A contact-type surface roughness tester was used to measure the laser-polished specimen’s average surface roughness (Sa). The three-point method of surface leveling produced the leveled surface. The form of the surface was extracted from the leveled surface by a polynomial of degree 2, resulting in form error and a surface without deviation. The experiment was designed and analyzed using a central composite design. Surface roughness improved from an average initial range of 15 ± 2.2 µm to a final average of 6.44 µm and 2.74 µm (average 57.06% reduction with maximum 81.73% reduction), representing better improvement. High laser energy density was associated with higher form error and waviness components. In conclusion, laser polishing with a line-focused beam is an effective method for cost-effectively polishing larger areas.

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Laser Polishing of Additive Manufactured Cobalt Chrome Alloy by Continuous Wave Line-Focused Beam: A Response Surface Methodology-Based Approach for Improving Surface Finish

  • Abhishek Kumar,
  • Cheruvu Siva Kumar,
  • Ashish Kumar Nath

摘要

Direct metal laser sintering (DMLS) is an additive manufacturing process where a laser selectively sinters metal powder particles, fusing them to create a solid part. Post-processing techniques are essential for additive manufacturing (AM) to achieve printed parts’ desired final properties, functionality, and aesthetics. A high-intensity laser beam is used in laser polishing to heat and melt the item’s surface. Because the molten material reflows and hardens, the surface becomes smoother. Surface flaws such as burrs or roughness can be removed selectively using laser polishing without altering the overall dimensions of the part. Cobalt–chromium alloy is used as a substrate for fabricating surgical and dental implants due to its high weight-to-strength, biocompatibility, and toxicity. The study aimed to improve the surface finish of the lateral or side surfaces of an additively manufactured cobalt chrome alloy by changing process parameters such as laser power and scan speed. A contact-type surface roughness tester was used to measure the laser-polished specimen’s average surface roughness (Sa). The three-point method of surface leveling produced the leveled surface. The form of the surface was extracted from the leveled surface by a polynomial of degree 2, resulting in form error and a surface without deviation. The experiment was designed and analyzed using a central composite design. Surface roughness improved from an average initial range of 15 ± 2.2 µm to a final average of 6.44 µm and 2.74 µm (average 57.06% reduction with maximum 81.73% reduction), representing better improvement. High laser energy density was associated with higher form error and waviness components. In conclusion, laser polishing with a line-focused beam is an effective method for cost-effectively polishing larger areas.