Abstract
In this paper, a novel surface finishing method of cone annular beam laser re-melting (CALR) is proposed which aims at optimizing the side surface quality of AlSi10Mg parts produced by directed energy deposition. Meanwhile, a feature-based characterization method was conducted to realize the multiscale analysis of the topographic features. The results show that the developed CALR is a powerful tool which can greatly reduce the surface roughness: the final optimal aluminum alloy thin-walled parts with a roughness of 7.1 µm was obtained, which was 68.3% less than the original roughness of 22.4 µm without the implementation of CALR. The optimization mechanism reveals the roughness reduction was mainly attributed to the elimination of the stair-step effect, while the role of powder particle features was much less significant on roughness reduction of the overall surface. The CALR method together with the feature-based surface characterization provides an innovative solution for side surface quality optimization for laser additive manufacturing.
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