Post-processing of additively manufactured metal parts by ultrashort laser pulses for high-quality net shape geometries and advanced functionality

Additive manufacturing by means of laser-based powder bed fusion (LPBF) offers high flexibility with respect to the generation of individualized and light-weight metal parts. However, the produced parts are typically attached to support structures and deviate a few tens of micrometers from the targeted final component in geometrical net shape and surface roughness due to the melt-based fusion process. Therefore, different post-processing techniques were examined in the past to resolve the mentioned quality drawbacks. In our work, we investigated the potential of post-processing of LPBF-generated Ti6Al4V parts with ultrashort pulse laser ablation. As a result, the support structures were effectively removed, the surface roughness was reduced by 81% and complex geometries with high shape accuracy were fabricated. Furthermore, the LBPF-generated parts were laser surface structured to investigate the potential of post-processing with ultrashort laser pulses for advanced functionality, such as water-repellent surfaces. The generation of surface structures on the LPBF-generated Ti6Al4V part changed the wetting behaviour from hydrophilic to hydrophobic with an increased contact angle from 73 degrees up to 130 degrees.

Automated summary

The study explored post-processing of LPBF-generated Ti6Al4V parts using ultrashort pulse laser ablation, which successfully removed support structures, reduced surface roughness by 81%, and fabricated complex geometries with high shape accuracy. Additionally, laser surface structuring of the parts changed the wetting behavior from hydrophilic to hydrophobic, increasing the contact angle from 73 degrees to 130 degrees.