1. Effect of electropolishing on ultrasonic cavitation in hybrid post-processing of additively manufactured metal surfaces
- Author
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Jeon, Ji Ho, Panpalia, Navjyot, Rashid, Asif, and Melkote, Shreyes N.
- Abstract
This investigation centered on fundamental understanding of a hybrid post-processing method that synergistically combines electrochemical polishing and ultrasonic cavitation to improve the surface roughness and mechanical properties of additively manufactured parts efficiently and simultaneously in a single step. High-speed imaging was utilized to understand the effect of the DC bias applied during electropolishing on the cavitation generated at various ultrasonic amplitudes. This was aimed at validating the hypothesis that the hybrid process is characterized by more bubbles than with ultrasonic excitation alone, and, in the presence of the DC bias, the bubbles are transported from the cathode to the anode (workpiece) where their impacts cause surface hardening. High-speed imaging confirmed a higher bubble count in the hybrid process than in the cavitation-only process at different ultrasonic amplitudes. Microhardness measurements confirmed that the hybrid process yielded higher microhardness compared to cavitation peening alone, while microhardness in electrochemical polishing showed only incremental changes. This observation was also corroborated by the grain size measurements, with the hybrid process exhibiting more grain refinement than cavitation-only or electropolishing-only post-processing modes. Surface topography analysis revealed minimal improvement in surface roughness due to cavitation-only, emphasizing the importance of the hybrid process in enhancing both surface roughness and the mechanical properties. Scanning electron microscope (SEM) images showed randomly distributed micro-dimples on the surface produced by the hybrid process at the highest ultrasonic amplitude, attributed to the increased number of cavitation bubbles. This research provides fundamental insights into why the hybrid process excels in simultaneously reducing surface roughness and achieving superior surface microhardness.
- Published
- 2024
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