TY  - CONF
A1  - Schröpfer, Dirk
T1  - Influence of Ultrasonic-Assisted Milling on Surface Integrity of Additively Manufactured Components Using DED-Arc/GMAW
N2  - Additive manufacturing (AM) is increasingly used for producing complex metallic com-ponents. Subsequent machining is essential to achieve final geometries and surface conditions. The resulting surface integrity, particularly the near-surface residual stress state, plays a crucial role in component performance and fatigue life. This study inves-tigates the potential of ultrasonic-assisted milling (USAM), a hybrid machining process, to improve surface integrity and machinability compared to conventional milling (CM). Three materials were investigated, two difficult-to-cut materials CoCr26Ni9Mo5W and FeNi36 and a low-alloy steel S355J2C. The CoCr26Ni9Mo5W and FeNi36 were addi-tively manufactured via DED-Arc and then machined with varying cutting speeds and feed rates within a Design of Experiments. USAM exhibited enhanced machinability and surface integrity, particularly at low cutting speeds, by reducing cutting forces up to 40% and shifting near-surface residual stresses from tensile to compressive. For S355J2C, USAM reduced cutting forces by approximately 45% and induced surface-near compressive residual stresses up to approximately -700 MPa, leading to a 11% higher fatigue strength compared to CM. These findings highlight the advantages of ultrasonic assistance in post-AM machining, offering enhanced fatigue performance and surface quality for various metallic materials.
T2  - 4th International Conference on Advanced Joining Processes 2025
CY  - Coimbra, Portugal
DA  - 16.10.2025
KW  - Ultrasonic-assisted milling
KW  - Additive manufacturing
KW  - Surface integrity
KW  - Fatigue strength
KW  - Residual stress
PY  - 2025
AN  - OPUS4-65051
LA  - eng
AD  - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany
ER  -