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Opportunities of Surface Science in Enhancing Reliability of Parts Fabricated via Metal Additive Manufacturing

19 Nov 2024

This presentation will be divided into two sections, each addressing key challenges in metal additive manufacturing (AM). The first part will focus on the issue of high surface roughness inherent in metal AM parts, often caused by the layer-by-layer nature of the process. Factors such as deposition process parameters, feedstock material, part design, and fusion mechanisms contribute to this limitation.

At the CoMPASS Research Laboratory, ISU, a sustainable semi-dry electro-mechanochemical surface finishing technique using dry electrolyte media has been developed to enhance the surface quality of nitrogen-strengthened austenitic steel produced via the L-DED process. Experimental results show significant surface quality improvements, with Sa and Sq reductions of 62% and 68% on the top surface and 73% and 79% on the side surface, respectively. The second part of the presentation will examine how the selection of alloying elements in the surface layer impacts friction, wear, and corrosion behavior. Specifically, the addition of tungsten (W) and molybdenum (Mo) to Co-Cr alloys under dry and simulated saliva-lubricated conditions will be analyzed for dental implant reliability. Distinct response differences underscore the importance of surface science in improving metal AM part performance. Attendees will gain a deeper understanding of advanced surface finishing techniques and material selection strategies for enhancing metal AM components.

Speaker: Dr. Sougata Roy, Assistant professor, Iowa State University