Laser polishing of cobalt chrome alloy fabricated by laser powder bed fusion process: design of experiment-based approach for reducing surface roughness

• Published in: International journal of advanced manufacturing technology Vol. 134; no. 3-4; pp. 1245 - 1264
• Main Authors: Kumar, Abhishek, Ramadas, Harikrishnan, Samal, Bijaya Bikram, Kumar, Cheruvu Siva, Nath, Ashish Kumar
• Format: Journal Article
• Language: English
• Published: London Springer London 01-09-2024; Springer Nature B.V
• Subjects: Beds (process engineering); CAE) and Design; Chromium; Cobalt base alloys; Computer-Aided Engineering (CAD; Design of experiments; Engineering; Industrial and Production Engineering; Intermetallic compounds; Laser ablation; Laser beam melting; Lasers; Mechanical Engineering; Media Management; Melting; Microhardness; Optimization; Original Article; Parameter identification; Parameter modification; Polishing; Powder beds; Surface finish; Surface properties; Surface roughness; Variance analysis; Cobalt chrome; Laser powder bed fusion; Surface roughness; Pulse laser polishing; Analysis of variance
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-024-14101-w

The present research aims to improve the surface quality of laser powder bed fusion (LPBF) built cobalt chrome alloy (CoCr) by pulse laser remelting. The laser power, overlap percentage, and spot diameter are varied to determine the best parameters for laser polishing. The microhardness and microstructural changes associated with pulse laser remelting are described. Surface morphology and surface roughness parameters are reported for various laser remelting parameters. Among the three different spot diameters, 1, 2, and 3 mm, the maximum (> 50%) reduction in surface roughness was obtained for 2 mm with 1J laser energy and 50%
X
and 20%
Y
as well as 20%
X
and 50%
Y
overlaps. A DoE- and RSM-based approach has been utilized for parametric optimization of the surface roughness. The squared laser power is identified as a critical parameter by ANOVA. A Pareto chart confirms the significance of squared laser power across spot diameters. Optimization suggests that a 2-mm spot diameter works best with specific parameters to produce a better surface finish. However, the nanosecond order laser pulses have a limitation on the depth of surface modification without severe ablation and thereby on the reduction in the surface roughness.