15-Dec-21

Post-processing of AM Parts
(Integration of techniques)

Radha Raman Mishra, Ph. D.

Course Instructor & Assistant Professor
Department of Mechanical Engineering

Introduction
• Post processing: final step of the manufacturing process which offers –
 smoothing and
 strengthening

• Despite many advantages of AM over traditional manufacturing, it is still imperfect.

• AM parts can still have poor surface finishes, and the production method can affect
the mechanical properties of the component.

• The main objective of post-processing is to eliminate potentially dangerous defects

• Post processing methods can include –

 heat treatment (to reduce the stress on components)
 separating the components from support structure
 surface finishing (CNC machining, blasting and polishing)
• The post processing of AM parts can be just as vital as the fabrication itself. 2

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Issues in AM
Surface roughness achieved in different AM processes
• Demand for better materials.
• Existing CAD systems.
• Data management (Size of STL file)
• Low-volume production
• Financial overheads
• Surface Quality of Products

Kumbhar, N. N., & Mulay, A. V. (2018). Post processing methods used to improve surface finish of products which are manufactured by additive manufacturing technologies: a
review. Journal of The Institution of Engineers (India): Series C, 99(4), 481-487. 3

Issues in AM
To minimize the Stair casing
a CAD Model b Slicing c Actual output d Stair casing effect effect, the possible approaches
are –
• Control over parameters
 part orientation
 layer thickness and
 orientation of material
deposition
• Post-processing techniques
Effect of reducing layer thickness

Kumbhar, N. N., & Mulay, A. V. (2018). Post processing methods used to improve surface finish of products which are manufactured by additive manufacturing technologies: a
review. Journal of The Institution of Engineers (India): Series C, 99(4), 481-487. 4

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Post-processing methods

Classification of Post-processing methods

Different raw materials
Nature of the process

Kumbhar, N. N., & Mulay, A. V. (2018). Post processing methods used to improve surface finish of products which are manufactured by additive manufacturing technologies: a
review. Journal of The Institution of Engineers (India): Series C, 99(4), 481-487. 6

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Thermal Post-Processing

• Hot isostatic pressing

• Heat treatment
 Solution HT
 T6 HT

Optical micrographs presenting defects. (a) Electron beam melting

(EBM) part (b) after the hot isostatic pressing (HIP) treatment.

Schematic diagram of SEM micrographs. (a,b) as-built. (c,d) HIP. (e,f) HIP + HT

Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 7

Laser Peening

Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 8

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Laser Polishing
• During laser polishing, morphology apexes can
reach the melting temperature rapidly when the
energy source irradiates the material surface.
• The liquid material redistributes to the same
level after molten-pool formation because of the
effect of gravity and surface tension.
• Once the laser beam stops scanning the surface,
the temperature of the heat-affected zone (HAZ)
drops rapidly, resulting in the solidification of the
molten pool, and the surface roughness reduces
accordingly

(a) Overview of the substrate and laser-polished region. (b)

Microstructure of the laser-polished region. (c) Microstructure of the
substrate. (d) XRD profiles.
Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 9

Machining and Abrasive Finishing

SLM-ed AlSiMg0.75
Difference in surface finish for
an untreated and CNC
machined part

(a) conventional diamond turning (b) ultrasonic elliptical vibration-assisted machining

Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 10

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Machining and Abrasive Finishing

Micro-blasting of SLM-ed tubular lattice structure. (a) setup. (b) lattice structure before micro-blasting. (c) after blasting

Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 11

Impact of post-processing

True stress strain plots of 3D printed samples with different printing speeds: (a) 88 μm (fast) and (b) 110 μm (slow) respectively.
In each plot, the three curves correspond to three different treatments including 3D printing (blue), 3D printing and 900 °C heat
treatment (red) and 3D printing, 900 °C hot forging and 900 °C heat treatment (yellow)

Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 12

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Impact of post-processing

Mean values of conventional Vickers hardness of fast (blue) and slow (yellow) 3D printed samples for three different treatments, namely direct 3D
printing, 900 °C heat treating after printing, and 900 °C forging (900°C H) and 900 °C heat treatment after printing (900°C F+900°C H).

Peng, X., Kong, L., Fuh, J. Y. H., & Wang, H. (2021). A Review of Post-Processing Technologies in Additive Manufacturing. Journal of Manufacturing and Materials Processing, 5(2), 38. 13

Thank you
All the best for Comprehensive Examination

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