Comparison of Ultrasonic Surface Treatment Methods Applied to Additively Manufactured Ti-6Al-4V Alloy

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Abstract

Introduction. Selective Laser Melting (SLM) of metal powders enables the fabrication of parts with arbitrary geometries, which is unattainable through conventional manufacturing technologies. The main disadvantages of the method include high surface roughness, resulting from metal spattering, spheroidization, partial melting and powder adhesion, as well as difficulties with finishing complex surface areas. One effective approach for processing such parts is the application of ultrasonic liquid technologies, where cavitation bubbles act as working bodies, penetrating and performing work on any area of the surface. The purpose of this study is to determine the influence of different types of ultrasonic treatment on the surface properties obtained by selective laser melting through comparative testing. Materials and methods. Samples made from Ti-6Al-4V titanium alloy, manufactured using selective laser melting on an EOS M280 machine, were investigated. For ultrasonic treatment, a rod-shaped magnetostrictive vibratory system was used, with the end of the emitter positioned 20 mm from the side surface of the sample. A etching solution (3% HF + 5% HNO3 + H2O) was used as a liquid medium to remove the oxide film that hinders the effect of cavitation. Cavitation-erosion (CET) treatment, cavitation-abrasive (CAT) treatment, and additionally, ultrasonic surface plastic deformation (USPD) were performed. After treatment, the surface condition, roughness, and sub-microgeometry were assessed for all samples. The microstructure of the USPD-treated samples was also investigated. Results and discussion. A high-speed imaging method was used to compare the main mechanisms of interaction with the surface during CET and CAT. During CET, collapsing and pulsating cavitation clusters are observed, located at the points of highest peaks and valleys on the surface. During CAT, the micro-cutting action of abrasive particles is added. These particles receive shock waves generated by collapsing bubbles, hit the surface, and undergo oscillatory, rotational, and longitudinal movements. Comparison of the surface condition dynamics revealed that CET enables complete removal of surface defects down to the melt tracks. CAT removes some surface defects while deforming the remaining ones. During USPD, spherical defects are crushed, forming large flat areas. All types of ultrasonic treatment reduce surface roughness: Ra is reduced by 33% during CET, by 43% during CAT, and by 52% during USPD. However, Rmax is lowest with CAT. The microstructure after USPD is characterized by a hardened layer with a depth of approximately 100 µm and an increase in microhardness up to 35%. However, after USPD, defects in the form of cracks, partially deformed spheres, and the presence of untreated deep surface depressions are formed in the surface layer, which significantly reduces performance characteristics. Therefore, it is advisable to perform CET or CAT before USPD to remove surface defects.

About the authors

S. K. Sundukov

Email: sergey-lefmo@yandex.ru
Ph.D. (Engineering), Associate Professor, Moscow Automobile and Road Construction State Technical University (MADI), 64 Leningradsky prospect, Moscow, 125319, Russian Federation, sergey-lefmo@yandex.ru

R. I. Nigmetzyanov

Email: lefmo@yandex.ru
Ph.D. (Engineering), Associate Professor, Moscow Automobile and Road Construction State Technical University (MADI), 64 Leningradsky prospect, Moscow, 125319, Russian Federation, lefmo@yandex.ru

V. M. Prikhodko

Email: prikhodko@madi.ru
D.Sc. (Engineering), Professor, Moscow Automobile and Road Construction State Technical University (MADI), 64 Leningradsky prospect, Moscow, 125319, Russian Federation, prikhodko@madi.ru

D. S. Fatyukhin

Email: mitriy2@yandex.ru
D.Sc. (Engineering), Associate Professor, Moscow Automobile and Road Construction State Technical University (MADI), 64 Leningradsky prospect, Moscow, 125319, Russian Federation, mitriy2@yandex.ru

V. K. Koldyushov

Email: v.koldyushov@list.ru
Moscow Automobile and Road Construction State Technical University (MADI), 64 Leningradsky prospect, Moscow, 125319, Russian Federation, v.koldyushov@list.ru

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