PSI - Issue 56

Sai Kumar Balla et al. / Procedia Structural Integrity 56 (2024) 41–48 Author name / Structural Integrity Procedia 00 (2019) 000 – 000

47

7

components followed by wire EDM. Maximum peaks and valleys are observed in as-built and chemical anodizing conditions, which is unacceptable in applications. A completely smoother surface is obtained using micro milling and surface roughness of 0.256 µm is achieved successfully. Post processing helps reduce surface roughness in all conditions and reduced by 60%, 50%, 82.5% and 98.8% in sand blasting, chemical anodizing, wire-EDM and micro milling, respectively compared with as-built samples. The microhardness and surface roughness of post processed samples are compared with as-built condition for AlSi12 alloy and represented in Fig. 5. It is observed that, microhardness had increased for micro-milling and sand blasting conditions where as it had been reduced with wire EDM and electropolishing compared to as-built AlSi12 samples. For micro milled samples, microhardness increased due to work hardening on the milled surface where as in sand blasted also helps slightly increase the microhardness of the AlSi12 alloy in the treated area due to work hardening caused by the mechanical impact of the abrasive particles. Electropolishing reduces the microhardness of the AlSi12 alloy in the treated area. This is because it selectively removes material from the surface and can remove work-hardened layers generated during prior machining or mechanical treatment and wire-EDM tends to induce localized heat-affected zones, potentially reducing microhardness. 4. Conclusions In this experimental work, AlSi12 alloy samples are successfully fabricated using LPBF process and adopted different post-processing techniques on the surfaces to improve the surface quality of samples. The surface roughness is measured for all post-processed samples and compared it with as-built conditions to evaluate the effect of post processing on the surface roughness of LPBF-processed AlSi12 alloy components and it was concluded that:  Post processing techniques like sand blasting, chemical anodizing, micro milling and wire EDM can be used even to improve the surface quality of AlSi12 alloy with minute features.  Micro-milling s average surface roughness (Sa) is reduced by up to 98.8% and increased microhardness from 78.64 HV to 113.2 HV compared to as-built conditions.  Micro-milling is a promising approach for finishing complex metallic additively manufactured parts with minimal complexity, followed by wire EDM. References Abhilash, P. M., & Chakradhar, D. (2022). Effect of wire material and discharge energy on productivity and surface integrity of WEDM processed Inconel 718. Advances in Materials and Processing Technologies , 8 (4), 4698 – 4719. https://doi.org/10.1080/2374068X.2022.2079590 Cao, L., Li, J., Hu, J., Liu, H., Wu, Y., & Zhou, Q. (2021). Optimization of surface roughness and dimensional accuracy in LPBF additive manufacturing Build platform. Optics and Laser Technology , 142 (May), 107246. https://doi.org/10.1016/j.optlastec.2021.107246 de Oliveira Campos, F., Araujo, A. C., Jardini Munhoz, A. L., & Kapoor, S. G. (2020). The influence of additive manufacturing on the micromilling machinability of Ti6Al4V: A comparison of SLM and commercial workpieces. Journal of Manufacturing Processes , 60 (February 2019), 299 – 307. https://doi.org/10.1016/j.jmapro.2020.10.006 Diegel, O., Nordin, A., & Motte, D. (2019). Additive Manufacturing Technologies. https://doi.org/10.1007/978-981-13-8281-9_2 Kaynak, Y., & Tascioglu, E. (2023). Finish machining-induced surface roughness , microhardness and XRD analysis of selective laser melted Inconel 718 alloy. Procedia CIRP , 71 (March), 500 – 504. https://doi.org/10.1016/j.procir.2018.05.013 Kumar, A., Sudarshan, A., Mathias, S., Shrivastava, A., & Raghupatruni, P. (2021). Influence of post-processing techniques on the microstructure , properties and surface integrity of Al – Si – Mg alloy processed by laser powder bed fusion technique. 425 (August). Lesyk, D. A., Dzhemelinskyi, V. V., Martinez, S., Mordyuk, B. N., & Lamikiz, A. (2021). Surface Shot Peening Post-processing of Inconel 718 Alloy Parts Printed by Laser Powder Bed Fusion Additive Manufacturing. Journal of Materials Engineering and Performance , 30 (9), 6982 – 6995. https://doi.org/10.1007/s11665-021-06103-6 Li, B. Q., Li, Z., Bai, P., Liu, B., & Kuai, Z. (2018). Research on surface roughness of AlSi10Mg parts fabricated by laser powder bed fusion. Metals , 8 (7), 1 – 10. https://doi.org/10.3390/met8070524 Liu, Y., Liu, C., Liu, W., Ma, Y., Tang, S., Liang, C., Cai, Q., & Zhang, C. (2019). Optimization of parameters in laser powder deposition AlSi10Mg alloy using Taguchi method. Optics and Laser Technology , 111 (March 2018), 470 – 480. https://doi.org/10.1016/j.optlastec.2018.10.030 Sagbas, B., Gencelli, G., & Sever, A. (2021). Effect of Process Parameters on Tribological Properties of Ti6Al4V Surfaces Manufactured by