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Since its inception in , SAE International has been involved with the production of materials and process of manufacturing in the mobility industry. As technologies evolve and processes change, SAE is committed to the global standardization of such processes and technologies today, including modern production practices like additive manufacturing (AM).
The AM process offers benefits in speed, simplicity, reliability and cost in parts production. The ability to produce lightweight parts through additive manufacturing can also be beneficial in the drive toward electrification as lighter parts can help extend battery life.
Understanding the materials that are compatible with additive manufacturing processes is an essential part of AM process success. AM materials include a variety of polymers, metals, composites, and ceramics. Each material is distinguished from another material by microstructure, mechanical and physical properties, and life cycle.
10 Surfacing Finishing Techniques of Metal Additive Manufacturing
Having explored the primary motivations behind finishing metal additive components, let&#;s delve into an overview of ten commonly used surface finishing techniques that can enhance your part&#;s functionality and performance:
1. Media Blasting
Here, compressed air is used to propel a blast media, such as sand, stainless steel shot, or glass beads, against the part to reduce surface roughness. This process is useful in removing surface imperfections.
2. Shot Peening
Shot peening is similar to media blasting, but with a different goal in mind. Instead of removing imperfections from the surface of your object, this process is used to increase its strength and durability.
During shot peening, pressurized air shoots metal or plastic beads at a surface, causing changes in the mechanical properties of the surface (i.e. resistance to wear).
3. Green Sanding
This is useful for reducing the appearance of printed layer lines and other imperfections. Green parts are relatively soft before sintering, so you can smooth out imperfections with a scouring pad or sandpaper before sintering.
4. Tumble Finishing
During tumble finishing, your parts are placed in a barrel along with water, an abrasive media, and a compounding agent. The rotation of the barrel causes everything to tumble down upon itself, causing friction and abrading the parts.
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This process works well with large or small parts, though it&#;s best-suited for parts with simple geometries. Tumble finishing parts with complex geometries can lead to non-uniform finishes.
5. Vibratory Finishing
Similar to tumble finishing, vibratory finishing is another solution for finishing a large number of parts simultaneously.
During this process, your parts, media, and compounds are placed into a vibratory tub or bowl. The vibratory action causes media and parts to grind against one another, deburring and/or polishing them.
The process can be wet or dry, and very gentle or aggressive, depending on your desired surface qualities.
6. Abrasive Flow Machining
During this type of internal surface finishing, a viscous, abrasive material is forced through the part, smoothing burrs, polishing surfaces, and removing metal. This type of additive manufacturing finishing uses a hydraulic ram to drive media through your part, creating a &#;slug&#; of abrasive material that molds itself to the part.
7. Electrochemical Polishing
An alternative to abrasive polishing, electrochemical polishing uses a chemical etchant stimulated by an electrical current to smooth and treat the internal and external surfaces of a part. This process is inexpensive, though the etchant and waste products must be handled and disposed of properly.
8. Wire Brushing
This involves using a handheld brush, drill, or grinder for deburring, edge blending, and removing surface imperfections.
9. Heat Treatments
Similar to shot peening, heat treatments strengthen your parts by reducing tensile pressure. Heat treatments can also be used to increase density or help form parts into your final, desired shape.
10. Traditional Machining
Metal additive manufacturing post-processing can include traditional methods associated with subtractive manufacturing, such as milling and grinding. These operations come into play when your manufacturer needs to further remove material to meet tolerance and surface specs.
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