Improving Surface Finish of 3D-printed Metals by Ultrasonic Nanocrystal Surface Modification

Poor surface finish of 3D-printed metals significantly deteriorates their corrosion, wear and fatigue resistance. Ultrasonic nano-crystal surface modification (UNSM) is an innovative surface processing technique that utilizes low amplitude ultrasonic frequency vibrations superimposed on a static load to generate plastic deformation on a metal surface to its improve properties and performance. In this study, we investigate the effect of UNSM on the surface finish of 3D-printed metals. An aluminum AlSi10Mg alloy fabricated by direct metal laser sintering (DMLS) was used as an example. It has been demonstrated that UNSM can significantly improve surface finish of 3D-printed aluminum alloy. For example, the surface roughness of the AlSi10Mg alloy was decreased from 18 to 3.5 μm. With a better surface finish, UNSM is expected to improve the properties and performance of 3D-printed metals.