Surface roughness evaluation when brushing heat-resistant alloy components

Abstract

AbstractNowadays, the combination of additive manufacturing technologies, together with the use of materials such as Inconel 718, opens new opportunities in the manufacture of aeronautical turbines. However, parts obtained directly through additive manufacturing are far from being considered suitable in their initial state, as they exhibit a poor surface finish that compromises their mechanical characteristics. Common among the defects found in such components are ridges stemming from thermal deformations during the powder fusion process. Therefore, abrasive brushing emerges as the prevalent method to rectify these surface imperfections. However, conventional roughness indicators prove insufficient in accurately characterizing such local defects during surface analysis. Consequently, this study investigates surface conditions of Inconel 718 parts produced through additive manufacturing, particularly focusing on defects caused by peak alignments along the powder fusion direction. Thus, a series of frontal brushing operations were conducted under varying conditions, with the aim of increasing the feed rate to address these defects. Subsequently, the effectiveness of the brushing process was assessed through the calculation of peak areas. The analysis of this indicator revealed that the maximum feed rate enabling complete removal of the peak marks was 500 mm/min.