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Procedia CIRP 00 (2018) 000–000
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Procedia 000–000
CIRP 71 (2018) 150–154
www.elsevier.com/locate/procedia

4th
4th CIRP
CIRP Conference
Conference on
on Surface
Surface Integrity
Integrity (CSI
(CSI 2018)
2018)

Laser
Laser Polishing
Polishing of
of Additive
Conference,Manufactured
Additive
28th CIRP Design Manufactured Superalloy
Superalloy
May 2018, Nantes, France
a b a b,c,
Fang
Fang Zhihao a, Lu Libinb, Chen Longfei a, Guan Yingchunb,c,*
A new methodology Zhihaoto analyze
, Lu Libinthe , Chen functional
Longfei , Guan and Yingchun
physical architecture
* of
existing School
products School of for
Energy an
Engineeringassembly oriented product
Xueyuan Road, family
Beijing 100191,identification
a
School of Energy and Power Engineering, Beihang University, 37 Xueyuan Road, Beijing 100191, P.R. China
a
b and Power Engineering, Beihang University, 37 Xueyuan Road, Beijing 100191, P.R. China
of Mechanical
b and Automation, Beihang University, 37 P.R. China
c School of Mechanical Engineering and Automation, Beihang University, 37 Xueyuan Road, Beijing 100191, P.R. China
cNational Engineering Laboratory of Additive Manufacturing for Large Metallic Components, Beihang University, 37 Xueyuan Road, Beijing 100191, P.R.
National Engineering Laboratory of Additive Manufacturing for Large Metallic Components, Beihang University, 37 Xueyuan Road, Beijing 100191, P.R.
China
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
China
* Corresponding author. Tel.: +86-010-8233-9691; fax: +86-010-8233-9691. E-mail address: guanyingchun@buaa.edu.cn
* Corresponding
Écoleauthor. Tel.:Supérieure
Nationale +86-010-8233-9691; fax: +86-010-8233-9691.
d’Arts et Métiers, E-mail address:
Arts et Métiers ParisTech, LCFC EAguanyingchun@buaa.edu.cn
4495, 4 Rue Augustin Fresnel, Metz 57078, France

* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu

Abstract
Abstract
Laser additive manufacturing has attracted considerable interest as a promising digital manufacturing technology in recent years. However,
Laser additive manufacturing has attracted considerable interest as a promising digital manufacturing technology in recent years. However,
Abstract
poor surface quality restricts its practical application. In this paper, we demonstrate the capability of laser polishing in rough surface of additive
poor surface quality restricts its practical application. In this paper, we demonstrate the capability of laser polishing in rough surface of additive
manufactured Inconel 718 alloy. Both as-received surface and laser-polished surface were analyzed carefully by Confocal Microscope,
manufactured Inconel 718 alloy. Both as-received surface and laser-polished surface were analyzed carefully by Confocal Microscope,
InScanning
today’s business environment,Energy
Electron Microscopy, the trend towards Spectrometer
Dispersive more product andvariety
X-rayandDiffraction.
customizationThe isresults
unbroken. Duethat
revealed to this development,
as-received the718
Inconel need of
alloy
Scanning Electron Microscopy, Energy Dispersive Spectrometer and X-ray Diffraction. The results revealed that as-received Inconel 718 alloy
agile
with and reconfigurable
surface roughness more production
than 7 systems
µm could emerged to cope
be reduced withthan
to less various
0.1 µmproducts
throughand product
laser families.
polishing (LP) To designMoreover,
process. and optimize production
microstructure,
with surface roughness more than 7 µm could be reduced to less than 0.1 µm through laser polishing (LP) process. Moreover, microstructure,
systems as well as
micro-hardness andtowear
choose the optimal
resistance product matches,
of laser-polished product
zone were analysis methods
investigated. are needed.
This preliminary studyIndeed, most the
has shown of the knownofmethods
potential aim to
laser polishing
micro-hardness and wear resistance of laser-polished zone were investigated. This preliminary study has shown the potential of laser polishing
analyze a product
in improving or one
surface product
finish family on of
and properties theadditive
physicalmanufactured
level. Different product families,
superalloy however,
without damage to may differ largely in terms of the number and
the substrate.
in improving surface finish and properties of additive manufactured superalloy without damage to the substrate.
nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production
© 2018
2018AThe
system. The
newAuthors. Published
methodology by Elsevier
is proposed Ltd. This
to analyze
B.V. is an open
existing access
products in article
view ofunder
theirthe CC BY-NC-ND
functional license
and physical architecture. The aim is to cluster
© 2018 The Authors. Published by Elsevier B.V.
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
these productsunder
Peer-review in new assembly oriented
responsibility product families
of the scientific committeefor the optimization
of the of existing assembly
4th CIRP Conference on Surface lines and the
Integrity creation
(CSI 2018).of future reconfigurable
Peer-reviewandunder
Selectionsystems. responsibility of
peer-review the scientific committee of the 4th CIRP of Conference onConference
Surface Integrity (CSI Integrity
2018). (CSI 2018).
assembly Based onunder
Datum responsibility
Flow Chain,ofthe thephysical
scientific committee
structure of the the 4th CIRP
products is analyzed. on Surface
Functional subassemblies are identified, and
a Keywords:
functionalLaser
analysis is performed.
polishing; Moreover, a Inconel
Additive manufacturing; hybrid718
functional
alloy； and physical architecture graph (HyFPAG) is the output which depicts the
Keywords: Laser polishing; Additive manufacturing; Inconel 718 alloy；
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
©1. Introduction theoretical density[10-12]. Nevertheless, it is hard to achieve
1.2017 The Authors. Published by Elsevier B.V.
Introduction theoretical density[10-12]. Nevertheless, it is hard to achieve
the desired surface finish
Peer-review under responsibility of the scientific committee of the 28th CIRP theDesign
desiredConference 2018. by
surface finish
SLM technology owing to the
by SLM technology owing to the
IN718 alloys have excellent fatigue resistance, hot influence of the scan tracks and layered structure[13-15]. The
IN718 alloys have excellent fatigue resistance, hot influence of the scan tracks and layered structure[13-15]. The
corrosionAssembly;
Keywords: resistance, wear
Design resistance
method; and good
Family identification weldability surface finish of a mechanical component has important
corrosion resistance, wear resistance and good weldability surface finish of a mechanical component has important
with outstanding high strengths at elevated temperatures[1, 2]. effects on its functionality, visual appearance and tribological
with outstanding high strengths at elevated temperatures[1, 2]. effects on its functionality, visual appearance and tribological
It has been extensively used in nuclear reactors, gas turbine properties[16]. Therefore, the SLM components need to be
It has been extensively used in nuclear reactors, gas turbine properties[16]. Therefore, the SLM components need to be
disks, spacecraft, rocket motors, pumps, tooling and so on[3, polished in the subsequent process.
disks, spacecraft,
1.4].Introduction rocket motors, pumps, tooling and so on[3, polished
of the in the range
product subsequentcharacteristics
process.
However, IN718 is difficult to be manufactured by Laser polishing and (LP) is a potential manufactured and/or
post-processing
4]. However, IN718 is difficult to be manufactured by Laser
assembled inpolishing
this system.(LP)In is context,
this a potential
the post-processing
main challenge in
conventional technologies because of low material removal technique used to reduce the surface roughness of the parts
conventional technologies because of low material removal technique used to reduce the surface roughness of the parts
Dueexcessive
rates, to the fastwear
tool development
and complexinin the shapedomainwith mazy of modelling
manufactured and analysis
by differentis nowprocesses
not only to cope withadditive
including single
rates, excessive and tool wear and complex in shape with mazy manufactured by different processes including additive
communication
inner structure[5-8]. an ongoing trend of digitization and products, a limited product
manufacturing[17]. rangecurrently
It has been or existing
used product families,
on metals[18],
inner structure[5-8]. manufacturing[17]. It has been currently used on metals[18],
digitalization, manufacturing
Selective Laser enterprises
Melting (SLM) is a are facing
powder bedimportant
additive diamonds[19],
but also to be ableand microandoptic
to analyze components[20].
to compare products to defineThe
Selective Laser Melting (SLM) is a powder bed additive diamonds[19], and micro optic components[20]. The
challenges
manufacturing in today’s
technique market
using environments:
a high power alaser continuing
as the technology
new product isfamilies.
based on It re-melting
can be causedthat
observed byclassical
laser irradiation
existing
manufacturing technique using a high power laser as the technology is based on re-melting caused by laser irradiation
thermal energy
tendency towardsinput to meltofand
reduction fuse development
product the metal powder timeslayer
and on the material
product familiessurface. The liquid
are regrouped material
in function of of peakor
clients and valley
features.
thermal energy input to melt and fuse the metal powder layer on the material surface. The liquid material of peak and valley
by layer toproduct
shortened get thelifecycles.
shape of theIn part directly
addition, based
there is anonincreasing
the CAD in moltedassembly
However, pool redistributes to the same horizontal level due
by layer to get the shape of the part directly based on the CAD in molted pool redistributes to the same horizontal levelfind.
oriented product families are hardly to due
model[4,of9].
demand In recent years,
customization, being SLM
at thetechnology
same time was
in aused
globalto to On
surface
the tension and
product gravity,
family level, and then thediffer
products rapidmainly
solidification
in two
model[4, 9]. In recent years, SLM technology was used to to surface tension and gravity, and then the rapid solidification
manufacturewith
competition the IN718 superalloy duetheto world.
its advantages of of molted pool metal(i)leads to the surface roughness andreduced
manufacture the competitors
IN718 superalloyall over This trend,
due to its advantages of main
when
characteristics:
of molted
the
pool metal leads
laser left[21].
the number
Compared
of components
to the surface
with
roughness
manual
(ii) the
reduced
polishing,
building
which is complex
inducing geometry
the parts
development with
fromthin wall
macro tofeatures,
micro type of components (e.g. mechanical, electrical,
when the laser left[21]. Compared with manual polishing, electronical).
building complex geometry parts with thin wall features, mechanical polishing and chemical–mechanical polishing, LP
having noresults
markets, tooling or mold costs lot involved, goodtosurface finish,
having no toolinginordiminished
mold costs involved,sizes due
good surfaceaugmenting
finish, is
Classical methodologies
mechanical
a highly efficient, high
considering mainly single
polishing and chemical–mechanical
flexible, and highly
products
polishing,
automated
LP
reduced
product process
varieties steps and
(high-volume density
to close
low-volume to 99.99%
production) of
[1]. or
is solitary,
a highly already
efficient, existing
high product
flexible, families
and highly analyze
automated the
reduced process steps and density close to 99.99% of
To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which
identify possible optimization potentials
2212-8271 © 2018 The Authors. Published by Elsevier B.V.
in the existing causes difficulties regarding an efficient definition and
production
2212-8271 © system,
2018 The it is important
Authors. Publishedtobyhave a precise
Elsevier B.V. knowledge comparison
Peer-review under responsibility of the scientific committee of the 4th CIRP Conference on Surfaceof different
Integrity product families. Addressing this
(CSI 2018).
Peer-review under responsibility of the scientific committee of the 4th CIRP Conference on Surface Integrity (CSI 2018).
2212-8271 © 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
2212-8271 © 2017 The Authors. Published by Elsevier B.V.
Selection and
Peer-review peer-review
under under
responsibility responsibility
of the of the scientific
scientific committee committee
of the 28th of the
CIRP Design 4th CIRP
Conference Conference on Surface Integrity (CSI 2018).
2018.
10.1016/j.procir.2018.05.088
 Fang Zhihao et al. / Procedia CIRP 71 (2018) 150–154
2 Author name / Procedia CIRP 00 (2018) 000–000
processing method. In recent 20 years, LP has been developed
for metallic materials, especially for difficult machining
metals. Schmidt et al. used Nd :YAG laser to polish the
aluminum alloys and the result shows initial surface
roughness of Ra = 1.37 μm was reduced to Ra≈ 0.47 μm[22].
Lamikiz et al. studied laser polishing the ST-100 built up by
selective laser sintering and achieved an 80.1% reduction of
the mean roughness (Ra from 7.8μm to 1.49μm)[18]. Ma et al.
proposed the surface roughness more than 5 μm could be
reduce to less than 1 μm on the additive manufactured
surfaces of Ti-6Al-4V and TC11[21]. Ukar et al. contrasted
the polishing effect of tool steel by CO2 laser and high-power
diode laser and reduced the Ra from 5.32μm to below 0.5
μm[23]. Bhaduri et al. investigated the influence of laser
fluence and pulse overlap parameters on resulting workpiece
surface roughness of 3D printed stainless steel (SS316L) and
a maximum reduction in roughness of over 94% (Sa:
from∼3.8μm to ∼0.2 μm Sa) was achieved at the optimised
settings (fluence of 9 J/cm2 and overlap factors of 95%)[24].
Abdullah et al. demonstrated the applicability of an ultra-short
(picosecond) pulsed laser for potential micro-polishing
applications on Inconel 718 and found that the initial Ra of
0.5 μm was reduced to 0.24 μm[16]. LP has been widely
applied to many metal materials, but there is little discussion
about the effect of laser polishing on SLM IN718 superalloy.
In our study, the rough surface of SLM IN718 superalloy
was polished by using nanosecond fiber laser. The purpose is
to study the effects of LP on the SEM IN718 surface. Through
optical microscope, scanning electron microscopy, laser
scanning confocal microscope, surface roughness measuring
instrument, XRD, Vickers hardness tester, ball-on-disk
tribometer, we discuss the changes in the microstructure,
surface morphology, roughness (Ra (arithmetical mean
deviation of the profile) and Rz (the point height of
irregularities) and mechanical properties of the material after
laser polishing.
2. Experimental setup
2.1. Material and laser polishing process
In order to realize our study of laser polishing, we decided
to use a nanosecond pulsed fiber laser (wavelength: λem. =
1060nm; average output power: P=100W; repetition
frequency: fp =1-1000kHz, pulse duration: tP=12-500ns; spot
diameter: 50μm).
A flat sample (length=50 mm, width=50 mm, thickness=5
mm) of Ni-based superalloy Inconel 718 (IN718) is used in
our LP experiment. The IN718 sample are manufactured by
SLM and the initial surface of as-received sample is
Ra=7.5±0.5μm. Due to the great roughness of the original
surface, laser polishing process with variable parameters was
adopted to get small surface waviness on the polished samples.
A set of laser polishing parameters by experimental
optimization are shown in Table 1. Before laser polishing, all
samples are cleaned ultrasonically in distilled water. The laser
polishing process takes places in a closed chamber, which is
filled with inert gas (Ar) to void unwanted oxidations on the
re-melting surface. After laser polishing, all samples are
151
cleaned ultrasonically in distilled water for subsequent testing
and characterization.
Table 1 Parameters of laser polishing process.
Scanning times Power (W) Scanning Overlap rate of
speed(mm/s) laser spot (%)
1-2 90 60 10
3-4 90 90 10
5-6 90 120 10
7-8 90 150 10
2.2. Surface characterization
The following equipments are used for surface morphology
analysis and roughness evaluation: OM (Nikon LV150N
optical microscope); SEM (Hitachi SU8010 field emission
scanning electron microscopy); LSCM (Keyence VK-X 100
series laser scanning confocal microscope); Surface roughness
measuring instrument (MarSurf M 300 C).
XRD patterns of samples before and after laser polishing
were measured by D/MAX2200pc to analysis the phase.
Micro-hardness was measured by FUTURE-TECH FM-800
Vickers, the loading force was chosen as 2.94 N, holding time
is 10 s and six indentation measurements are averaged for
each micro-hardness. Reciprocating dry sliding friction tests
were conducted using a ball-on-disk tribometer (UMT-2,
CETR, USA) to assess the friction and wear behavior of the
samples at the stroke length of 5mm, the oscillating frequency
of 1Hz and the applied load of 10 N for 15 min. A Si3N4 ball
(diameter of 5 mm) was used as the counterpart. The friction
coefficient can be obtained directly using the software on the
UMT-2 tribometer. The wear scars can be measured and
contracted by the Keyence LSCM.
3. Results and discussions
3.1. Surface morphology
After laser polishing, micro scale and macro scale
photographs of IN718 surface are shown in Fig.1. The Fig. 1
(f) shows the macro surface roughness variety after laser
polishing. The surface topography images of 3D profile and
2D OM of the original surface and polished surface are shown
in Fig.1 (a), (b), (c) and (d). Through the comparison between
Fig.1 (a) and Fig.1 (b), LP significantly improves the surface
finish of SLM IN718. From the Fig.1 (d), laser re-melting
tracks are observed on IN718 surface and it is caused by rapid
melting and solidification during laser irradiation. The
irradiated material reached the melting temperature in very
short time and part of the molten peak flowed into valley
driven by gravity and surface tension leading to the uniform
distribution of the liquid in the molten pool. When the laser
beam left, liquid material solidified at a high cooling rate. In
the end, the height difference of peak-to-valley on the original
surface is significantly reduced. The periodic stripes of the
polished surface were caused by laser scanning-track.
152 Fang Zhihao et al. / Procedia CIRP 71 (2018) 150–154
Author name / Procedia CIRP 00 (2018) 000–000
Fig.1. Surface topography images: 3D surface profile (a) and (b); OM (c) and
(d); Macroscopical photo (f).
The average surface roughness Ra and Rz of before and
after polishing IN718 samples were measured by surface
roughness measuring instrument and were verified by
analyzing surface topography images of LSCM. The
calculation results were listed in the Table 2. The IN718
superalloy by SLM was effectively polished, the Ra and Rz
approximately decreased from 7.5 μm to less than 0.1μm,
from 31μm to 0.6 μm, respectively.
Table 2 Surface roughness Ra and Rz of IN718 samples before and after laser
polishing.
Specimen Ra (μm) Rz (μm)
As-received 7.5±0.5 31±5
Laser polishing ≤0.1 0.6±0.1
3.2. Microstructure
The OM images of cross section of polished layer is
showed in Fig.2. It can be seen the thickness of laser re-
melting layer is about 120μm in the Fig.2 (a). On higher
magnification, the substrate microstructure of IN718 reveals
distinctive segregation patterns generated by layer scanning
paths in the Fig.2 (c) [9]. As shown in Fig.2 (b), the
indications caused by laser scanning during SLM were
eliminated after laser polishing.
Fig.2. The OM images of cross section of polished layer.
The SEM images of polished layer’s cross section are
shown in the Fig.3. The typical segregation patterns resulted
by the dendritic/cellular growth are observed in the Fig.3 (a)
and (d), which was formed in the process of SLM. The grain
structures in the bottom region of the polished layer was
shown in Fig.3 (b) and (e) and still maintain columnar
morphology, but the grain size decreases compared to the
substrate. In the top region of polished layer, the grain size
further decreases for the high cooling rate as shown in Fig.3
(c) and (f). It is known that the presence of more secondary
3
phases and carbides contribute to grain boundary pinning,
hence restrict grain growth. The matrix Inconel 718 alloy is γ
phase (Ni-Cr solid solution) and the γ'' phase (bct-Ni3Nb) is
the main strengthening phase forming a coherent precipitate
with γ phase in IN718[9]. The columnar γ'' phase precipitate
can be observed clearly in Fig.3. (f).
Fig.3. SEM images: (a) Substrate, (b) Bottom region of the polished layer, (c)
Top region of polished layer; Higher magnification (d), (e) and (f).
For the IN718 alloy, the X-ray pattern analysis is
challenging because of the γ and γ'' peaks overlap in the XRD
spectra for γ'' precipitates coherent with the γ matrix[1, 3].
The XRD profiles are shown in Fig. 4. For the polished
surface, the (111) peak significantly decreases, but the (200)
and (220) peaks increase. It is caused by the precipitation of
γ'' phase with grains refinement during the rapid melting and
solidification. Combination with the SEM results, it can be
found that laser polishing can refine grain and increase
precipitation strengthening phase γ'' in the polished layer.
Fig.4. The XRD profiles of samples before and after polishing.
3.3. Surface mechanical properties
3.3.1 Micro-hardness measurement
The micro-hardness distributions of polished IN718
superalloy is shown in Fig.5. The average hardness of
substrate of IN718 is about 345HV. After laser polishing,
the hardness of the polished surface increases by 27.5%
(to about 440HV) than that of the as-received material.
Obviously, LP improves the surface hardness of as-
received samples. Combined with the analysis of
microstructures, the precipitation strengthening of γ'' to γ
matrix is the main contributions for polished IN718
samples to their high surface hardness without weakness.
Besides this, the grain refinement caused by laser rapid
heating and cooling is beneficial for improving the
hardness of polished samples[9]. Consequently, the
higher hardness is owing to the combined effect of grain
 Fang Zhihao et al. / Procedia CIRP 71 (2018) 150–154
4 Author name / Procedia CIRP 00 (2018) 000–000
refinement and formation of precipitates by laser
polishing.
Fig.5. Micro-hardness distributions in cross section of polished sample.
3.3.2 Tribological performance
The tribological performance of material is vital to the
service life of the mechanical components [25-27]. Fig.6
shows the comparison of wear scars on polished and original
surface. It can be seen the wear scar of polished surface is
smaller than that of the original surface from the details of the
two wear scars. The maximum cross section areas of wear
scars on the polished and original surfaces are 6457.104 μm2
and 12338.163 μm2, the maximum depths of the wear scars
are 16.34 μm and 25.28 μm, respectively. Wear rate is used to
evaluate the wear resistant of the samples and it is calculated
by the following formula [28]:
Δv
W  (1)
L*D
where ΔV is the volume of the wear scar, L is the total sliding
distance and D is the applied load in the experiment.
Fig.6. Comparison of wear scars on polished and original surface: 3D surface
profile (a), Optical micrograph (c) and cross section (e) of polished surface;
3D surface profile (b), Optical micrograph (d) and cross section (f) of original
surface.
153
As shown in Fig.6, the wear rates of polished and original
surface are 0.517 and 0.987 mm3(N.m)-1, respectively.
Through the above discussion of the Fig.6, it can conclude
that the wear resistance of the SLM material has been greatly
improved (the wear rate increase by 90%) after laser polishing.
The main reason for the above phenomenon could be the
increase of surface hardness and the surface finish on the
polished surface.
Apart from the wear rate, the variation of friction
coefficient with sliding time of original surface and polished
surface is shown in Fig.7. It can be seen that the average COF
of polished surface decreases by 0.15 compared to that of
original surface. It indicates that the improvement of material
surface finish after laser polishing is helpful to the decrease
friction coefficient. Through the comprehensive analysis of
friction and wear properties about laser-polished surface. it is
known that the polished surface acts as a protective role and
effectively increases the wear performance during the sliding
process.
Fig.7. Coefficient of friction under reciprocating sliding for original surface
and polished surface.
4. Conclusions
This paper focuses on the feasibility of laser polishing on
SLM IN718 superalloy to improve surface finish. The main
experimental results and their analysis are as follows:
 Compared to the SLM surface, LP effectively improves the
surface finish. The result shows the Ra and Rz decreases
from 7.5μm to less than 0.1μm, from 31μm to 0.6μm,
respectively.
 Based on the microstructure and XRD results, the grain
size decreases and γ 〞 phase precipitate forms in the
polished layer for the high cooling rate during laser
polishing.
 The micro-hardness of the material surface increases from
345HV to 440HV after laser polishing.
 The COF and wear rate of laser polished IN718 surfaces
obviously declines relative to the original surface and it
indicates that the friction and wear properties are largely
enhanced by laser polishing.
154 Fang Zhihao et al. / Procedia CIRP 71 (2018) 150–154
Author name / Procedia CIRP 00 (2018) 000–000
Acknowledgements
This work was supported by the National Program of Key
Research in Additive Manufacturing and Laser Manufacturing
of China [grant no.2016YFB1102503]; National Natural
Science Fund of China [grant number 51705013]; Beijing
Natural Science Foundation [grant numbers J170002];
Fundamental Research Funds for the Central Universities
from Beihang University [project code KZ37025401].
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