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.zeige mehrzeige weniger

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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
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