Abstract
Burnishing is a Severe Plastic Deformation process having the potential to replace expensive finishing post processes. It is considered a super finishing process due to its results in terms of drastic roughness reduction. Also, additional advantages include the surface integrity improvement functionalized to the specific application. Even though burnishing is widely applied for surface improvement of conventional materials, knowledge about its effect on additively manufactured metals is still limited. This paper aims to fill this gap presenting experiments on roller burnishing on additively manufactured stainless steel in order to improve its tribological performance. The experimental campaign was carried out to find suitable process parameters able to drastically improve the tribological behavior of the final product. In particular, the influence of the burnishing forces on the whole surface quality has been addressed. The overall results demonstrate that the selected burnishing configuration is able to successfully modify the surface characteristics of the steel, making it appropriate for critical applications. Furthermore, the experimental findings allow to conclude that burnishing process can replace a series of post processes needed after additive manufacturing, drastically reducing the time and costs associated to the manufacturing process and meeting Industry 4.0 requirements.
Highlights
Additive manufacturing (AM), unlike conventional manufacturing, allows the production of near-net-shape products in a single step, suppressing intermediate component relocation steps from a machine to another and bringing significant cost drop in case of high-complexity parts [1]
More in detail, combining removal of low-quality outer layers and subsequent burnishing brought to a specific wear rate reduction up to 71% with respect to as printed samples, in comparison with the 40% given by the sole machining
The reasons for this improvement can be found in residual stresses and surface integrity enhancement induced by burnishing process, together with different contact area related to surface finish
Summary
Additive manufacturing (AM), unlike conventional manufacturing, allows the production of near-net-shape products in a single step, suppressing intermediate component relocation steps from a machine to another and bringing significant cost drop in case of high-complexity parts [1]. Typical issues concern (i) the presence on surface of stair-steps, adhered powder and residuals from support removal, (ii) poor accuracy related to positioning limitations of machines, shrinkage and residual stress-induced distortion, (iii) porosity arising from reduced bonding between particles/layers, (iv) anisotropy in microstructure and mechanical properties [2, 3]. These metallurgical faults, such as pores together with the molten pool boundaries, are preferred sites for localized corrosion [4]. They can decrease the ability of the alloy in forming a protective oxide layer, acting as traps for liquid solution in working environment
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