Title: Reducing surface roughness of metallic freeform-fabricated parts using non-tactile finishing methods

Authors: J.A. Ramos-Grez, D.L. Bourell

Addresses: Department of Mechanical and Metallurgical Engineering, Pontificia Universidad Catolica de Chile, Vicuna a Mackenna 4860, Santiago, Chile. ' Department of Mechanical Engineering, The University of Texas at Austin, Austin, TX 78712, USA

Abstract: Metallic parts created using current freeform fabrication processes have an unacceptably high surface finish (Ra » 1:0 mm) for many functional applications. This paper addresses the use of non-tactile laser polishing for surface finishing of commercial selective laser sintered iron±copper parts. A laser polishing window of energy density for roughness reduction up to a 37% of the original Ra value ranged between ~250 and 580 J cm-2. Several surface melting regimes are identified and analysed. The impact of oxidation on surface finish is discussed.

Keywords: copper based alloy; solid freeform fabrication; laser raster-scan; selective laser sintering; SLS; surface roughness; rapid prototyping; laser scanning; laser polishing; surface finishing.

DOI: 10.1504/IJMPT.2004.004944

International Journal of Materials and Product Technology, 2004 Vol.21 No.4, pp.297 - 316

Published online: 26 Jul 2004 *

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