Advanced Manufacturing: research of process parameters effects on surface quality of metal parts

Abstract

Advanced Manufacturing or Industry 4.0 is characterized by a set of technologies that contribute to the development of intelligent industrial processes. Among the technologies that encompass it, additive manufacturing deserves special attention because it provides greater flexibility and efficiency to the productive system. In additive manufacture, various types of materials can be considered, such as polymers, superalloys based on nickel, aluminum, titanium, different types of steels, as well as functional metal matrix composites. Typical applications are in the biomedical, aerospace and, more recently, automotive industries. Considering the complex physical, chemical and metallurgical interactions that occur in additive manufacturing, a great possibility of world-class research at the knowledge frontier is offered by varying process parameters and gaining a better understanding of processing conditions and properties. Therefore, a holistic investigation of the process is necessary, which involves developing new combinations of laser scanning parameters, evaluating their effects on the microstructure and properties of the material, and feedback the process by means of reliable measurements. Measurements including surface texture analysis and Barkhausen's magnetic noise make it possible to evidence the physical phenomena that occur during the manufacturing process, to correlate them with the intricate system of cause and effect inherent in the additive manufacturing process and, finally, improve them. The quality of the surface obtained in the additive manufacture of metal parts is a limiting factor in the application of this process and it is necessary to improve the roughness of the part. Milling is one of the main processes used to reduce roughness values. Thus, this work investigates the effect of the parameters of both processes (additive manufacture and milling) on the surface condition of maraging steel specimens 300. (AU)