Influence of Ultrasonic-Assisted Milling on Surface Integrity of Additively Manufactured Components Using DED-Arc/GMAW
- 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 toAdditive 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.…


| Autor*innen: | Dirk Schröpfer |
|---|---|
| Koautor*innen: | Lorenz Engelking, Mauro MadiaORCiD, Thomas Kannengießer, A. Eissel, K. Treutler, V. Wesling |
| Dokumenttyp: | Vortrag |
| Veröffentlichungsform: | Präsentation |
| Sprache: | Englisch |
| Jahr der Erstveröffentlichung: | 2025 |
| Organisationseinheit der BAM: | 9 Komponentensicherheit |
| 9 Komponentensicherheit / 9.2 Versuchsanlagen und Prüftechnik | |
| 9 Komponentensicherheit / 9.4 Integrität von Schweißverbindungen | |
| DDC-Klassifikation: | Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten |
| Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Angewandte Physik | |
| Freie Schlagwörter: | Additive manufacturing; Fatigue strength; Residual stress; Surface integrity; Ultrasonic-assisted milling |
| Themenfelder/Aktivitätsfelder der BAM: | Energie |
| Energie / Windenergie | |
| Material | |
| Material / Additive Fertigung | |
| Material / Degradationsmechanismen | |
| Veranstaltung: | 4th International Conference on Advanced Joining Processes 2025 |
| Veranstaltungsort: | Coimbra, Portugal |
| Beginndatum der Veranstaltung: | 16.10.2025 |
| Enddatum der Veranstaltung: | 17.10.2025 |
| Verfügbarkeit des Dokuments: | Datei im Netzwerk der BAM verfügbar ("Closed Access") |
| Datum der Freischaltung: | 09.12.2025 |
| Referierte Publikation: | Nein |
| Eingeladener Vortrag (wissenschaftliche Konferenzen): | Nein |

