CHEMICAL POST-PROCESSING METHODS FOR ENHANCING SURFACE PROPERTIES OF PARTS FABRICATED BY ADDITIVE MANUFACTURING: A REVIEW

Additive manufacturing is a rapidly developing field due to the production of complex geometry parts with rapid prototyping with a wide range of applications. In addition to the great advantages, Additive manufacturing produces components with relatively poor surface quality. For this reason, post-processing operations are inevitable to have ready-to-use products. Various post-processing operations including mechanical, chemical and thermal are being implemented to components fabricated by additive manufacturing processes. The purpose of this article is to review chemical post-processing operations and their effect on surface enhancement. This review study shows that chemical post-processing operations have great potential to improve surface aspects of components fabricated by additive manufacturing.

Keywords:

Additive manufacturing chemical post-processing, 3D printing, surface treatment,

PDF

___

[1] Huang, S.H., P. Liu, A. Mokasdar, and L. Hou, (2013) Additive manufacturing and its societal impact: a literature review, The International Journal of Advanced Manufacturing Technology, 67(5-8), 1191-1203.
[2] Bhavar, V., P. Kattire, V. Patil, S. Khot, K. Gujar, and R. Singh, (2014) A review on powder bed fusion technology of metal additive manufacturing, 4th International conference and exhibition on Additive Manufacturing Technologies-AM-2014, September 1-2, Bangalore, India.
[3] Ngo, T.D., A. Kashani, G. Imbalzano, K.T. Nguyen, and D. Hui, (2018) Additive manufacturing (3D printing): A review of materials, methods, applications and challenges, Composites Part B: Engineering, 143, 172-196.
[4] Galantucci, L.M., F. Lavecchia, and G. Percoco, (2009) Experimental study aiming to enhance the surface finish of fused deposition modeled parts, CIRP annals, 58(1), 189-192.
[5] McCullough, E.J. and V.K. Yadavalli, (2013) Surface modification of fused deposition modeling ABS to enable rapid prototyping of biomedical microdevices, Journal of Materials Processing Technology, 213(6), 947-954. N. Sunay, M. Kaya, Y. Kaynak / Sigma J Eng & Nat Sci 38 (4), 2027-2042, 2020
[6] Mazlan, S.N.H., M.R. Alkahari, F.R. Ramli, N.A. Maidin, M. Sudin, and A.R. Zolkaply, (2018) Surface Finish and Mechanical Properties of FDM Part After Blow Cold Vapor Treatment, Journal of Advanced Research in Fluid Mechanics and Thermal Sciences, 48(2), 148-155.
[7] Havenga, S., D. De Beer, P. Van Tonder, and R. Campbell, (2015) Effectiveness of acetone postproduction finishing on entry level FDM printed ABS artefacts, RAPDASA Conference Proceedings 2015, 4 – 6 November 2015, Roodevallei, Pretoria
[8] Łyczkowska, E., P. Szymczyk, B. Dybała, and E. Chlebus, (2014) Chemical polishing of scaffolds made of Ti–6Al–7Nb alloy by additive manufacturing, Archives of Civil and Mechanical Engineering, 14(4), 586-594.
[9] Handbook, A., (1994) vol. 5: Surface Engineering, ASM International, Materials Park, OH, 345-347.
[10] Handbook, A., (2004) Metallography and Microstructures, Vol 9, ASM International, Chemical and Electrolytic Polishing, Table 3 Applicability of electrolytes in Table 2 to electropolishing of various metals and alloys, 281-293.
[11] Wysocki, B., J. Idaszek, J. Buhagiar, K. Szlązak, T. Brynk, K.J. Kurzydłowski, and W. Święszkowski, (2019) The influence of chemical polishing of titanium scaffolds on their mechanical strength and in-vitro cell response, Materials Science and Engineering: C, 95, 428-439.
[12] Tyagi, P., T. Goulet, C. Riso, and F. Garcia-Moreno, (2019) Reducing surface roughness by chemical polishing of additively manufactured 3D printed 316 stainless steel components, The International Journal of Advanced Manufacturing Technology, 100(9-12), 2895-2900.
[13] Mohammadian, N., S. Turenne, and V. Brailovski, (2018) Surface finish control of additively-manufactured Inconel 625 components using combined chemical-abrasive flow polishing, Journal of Materials Processing Technology, 252, 728-738.
[14] Ramasawmy, H. and L. Blunt, (2007) Investigation of the effect of electrochemical polishing on EDM surfaces, The International Journal of Advanced Manufacturing Technology, 31(11-12), 1135-1147.
[15] Jain, S., M. Corliss, B. Tai, and W.N. Hung, (2019) Electrochemical polishing of selective laser melted Inconel 718, Procedia Manufacturing, 34, 239-246.
[16] Baicheng, Z., L. Xiaohua, B. Jiaming, G. Junfeng, W. Pan, S. Chen-nan, N. Muiling, Q. Guojun, and W. Jun, (2017) Study of selective laser melting (SLM) Inconel 718 part surface improvement by electrochemical polishing, Materials & Design, 116, 531-537.
[17] Tyagi, P., T. Goulet, C. Riso, R. Stephenson, N. Chuenprateep, J. Schlitzer, C. Benton, and F. Garcia-Moreno, (2019) Reducing the roughness of internal surface of an additive manufacturing produced 316 steel component by chempolishing and electropolishing, Additive Manufacturing, 25, 32-38.
[18] Kim, U.S. and J.W. Park, (2019) High-quality surface finishing of industrial three-dimensional metal additive manufacturing using electrochemical polishing, International Journal of Precision Engineering and Manufacturing-Green Technology, 6(1), 11-21.
[19] Handbook, M., Heat Treating, Cleaning and Finishing, Vol. 2. 1964, American Society for Metals, Metals Park, Ohio.
[20] Paunovic, M., (2000) Modern Electroplating 4th ed. ed M. Schlesinger and M. Paunovic, New York: John Wiley & Sons, New York, USA
[21] Kannan, S. and D. Senthilkumaran, (2014) Investigating the influence of electroplating layer thickness on the tensile strength for fused deposition processed ABS thermoplastics, International Journal of Engineering and Technology, 6(2), 1047-1052.
[22] Saleh, N., N. Hopkinson, R.J. Hague, and S. Wise, (2004) Effects of electroplating on the mechanical properties of stereolithography and laser sintered parts, Rapid prototyping journal. Chemical Post-Processing Methods for Enhancing … / Sigma J Eng & Nat Sci 38 (4), 2027-2042, 2020
[23] Kumar, T.N., M. Kulkarni, M. Ravuri, K. Elangovan, and S. Kannan, (2015) Effects of electroplating on the mechanical properties of FDM-PLA parts, i-Manager's Journal on Future Engineering and Technology, 10(3), 29.
[24] Nikzad, M., S. Masood, and I. Sbarski, (2011) Thermo-mechanical properties of a highly filled polymeric composites for fused deposition modeling, Materials & Design, 32(6), 3448-3456.
[25] Schlesinger, M. and M. Paunovic, (2011) Modern electroplating, Vol. 55. 2011: John Wiley & Sons, New York, USA.
[26] Zhang, Y., J.A. Abys, M. Schlesinger, and M. Paunovic, (2000) Tin and tin alloys for lead-free solder, Modern electroplating, 4th edn. Wiley, New York, 241-287.
[27] Angel, K., H.H. Tsang, S.S. Bedair, G.L. Smith, and N. Lazarus, (2018) Selective electroplating of 3D printed parts, Additive Manufacturing, 20, 164-172.
[28] Mäkinen, M., E. Jauhiainen, V.-P. Matilainen, J. Riihimäki, J. Ritvanen, H. Piili, and A. Salminen, (2015) Preliminary comparison of properties between Ni-electroplated stainless steel parts fabricated with laser additive manufacturing and conventional machining, Physics Procedia, 78, 337-346.
[29] Daneshmand, S. and C. Aghanajafi, (2012) Description and modeling of the additive manufacturing technology for aerodynamic coefficients measurement, Strojniški vestnik-Journal of Mechanical Engineering, 58(2), 125-133.
[30] Shorrock, C., (2018) Investigation and Conceptual Design Surrounding the Electroplating of Parts Created Through the Use of Additive Manufacturing (AM) Technologies 2018, University of Central Lancashire.
[31] Pyka, G., G. Kerckhofs, I. Papantoniou, M. Speirs, J. Schrooten, and M. Wevers, (2013) Surface roughness and morphology customization of additive manufactured open porous Ti6Al4V structures, Materials, 6(10), 4737-4757.
[32] Pyka, G., A. Burakowski, G. Kerckhofs, M. Moesen, S. Van Bael, J. Schrooten, and M. Wevers, (2012) Surface modification of Ti6Al4V open porous structures produced by additive manufacturing, Advanced Engineering Materials, 14(6), 363-370.
[33] Van Hooreweder, B., K. Lietaert, B. Neirinck, N. Lippiatt, and M. Wevers, (2017) CoCr F75 scaffolds produced by additive manufacturing: influence of chemical etching on powder removal and mechanical performance, Journal of the mechanical behavior of biomedical materials, 70, 60-67.
[34] de Formanoir, C., M. Suard, R. Dendievel, G. Martin, and S. Godet, (2016) Improving the mechanical efficiency of electron beam melted titanium lattice structures by chemical etching, Additive Manufacturing, 11, 71-76.
[35] Farber, E., Nazarov, D., Mitrofanov, I., Sufiiarov, V., Popovich, A., Maximov, M, (2020)Development of the titanium meshes by selective laser melting and chemical etching forusing as medical implants, Materials Today: Proceedings, 30, 746-751.
[36] Dobrzański, L., A. Dobrzańska-Danikiewicz, T. Gaweł, and A. Achtelik-Franczak, (2015) Selective laser sintering and melting of pristine titanium and titanium Ti6Al4V alloy powders and selection of chemical environment for etching of such materials, Archives of Metallurgy and Materials, 60(3A), 2040--2045.
[37] Chohan, J.S., R. Singh, K.S. Boparai, R. Penna, and F. Fraternali, (2017) Dimensional accuracy analysis of coupled fused deposition modeling and vapour smoothing operations for biomedical applications, Composites Part B: Engineering, 117, 138-149.
[38] Rajan, A.J., M. Sugavaneswaran, B. Prashanthi, S. Deshmukh, and S. Jose, (2020) Influence of Vapour Smoothing Process Parameters on Fused Deposition Modelling Parts Surface Roughness at Different Build Orientation, Materials Today: Proceedings, 22, 2772-2778. N. Sunay, M. Kaya, Y. Kaynak / Sigma J Eng & Nat Sci 38 (4), 2027-2042, 2020
[39] Mu, M., C.-Y. Ou, J. Wang, and Y. Liu, (2020) Surface modification of prototypes in fused filament fabrication using chemical vapour smoothing, Additive Manufacturing, 31, 100972.
[40] Rao, A.S., M.A. Dharap, J.V. Venkatesh, and D. Ojha, (2012) Investigation of post processing techniques to reduce the surface roughness of fused deposition modeled parts, International Journal of Mechanical Engineering and Technology, 3(3), 531-544.
[41] Espalin, D., F. Medina, K. Arcaute, B. Zinniel, T. Hoppe, and R. Wicker, (2009) Effects of vapor smoothing on ABS part dimensions, Proceedings from Rapid 2009 Conference & Exposition, 26-27 May 2009, Schaumburg, USA
[42] Singh, T.B., J.S. Chohan, and R. Kumar, (2020) Performance analysis of vapour finishing apparatus for surface enhancement of FDM parts, Materials Today: Proceedings.
[43] Diegel, O., A. Nordin, and D. Motte, (2019) A Practical Guide to Design for Additive Manufacturing 2019: Springer, Singapore
[44] Percoco, G., F. Lavecchia, and L.M. Galantucci, (2012) Compressive properties of FDM rapid prototypes treated with a low cost chemical finishing, Research Journal of Applied Sciences, Engineering and Technology, 4(19), 3838-3842.
[45] Colpani, A., A. Fiorentino, and E. Ceretti, (2019) Characterization of chemical surface finishing with cold acetone vapours on ABS parts fabricated by FDM, Production Engineering, 13(3-4), 437-447.
[46] Schmid, M., C. Simon, and G. Levy, (2009) Finishing of SLS-parts for rapid manufacturing (RM)–a comprehensive approach, Proceedings SFF, 1-10.
[47] Chohan, J.S. and R. Singh, (2017) Pre and post processing techniques to improve surface characteristics of FDM parts: a state of art review and future applications, Rapid Prototyping Journal.