Surface integrity of selective-laser-melted components

Selective-laser-melting (SLM) is an emerging rapid manufacturing technology allowing the production of components with complex geometries. Though the produced components' dimensions are close to the final dimensions, subsequent machining steps might be necessary. Therefore the resulting surface integrity of SLM-produced and subsequently machined components is crucial. In this study the surface integrity of ground and milled SLM-samples (18 Maraging 300) was analyzed, taking into account the layer orientation. By assessing depth profiles for hardness and residual stresses as well as by measuring the surface roughness, a first time comprehensive view of the correlations between layer orientation, machining process and surface integrity of SLM-samples was obtained. On the basis of these findings, the future potential of SLM can be revealed. The experiments were performed within the framework of the CIRP collaborative working group on Surface Integrity and the Functional Performance of Components. (C) 2010 CIRP.