Laser surface polishing of Ti-6Al-4V parts manufactured by laser powder bed fusion

Poor surface quality of Additively Manufactured (AM) components, can greatly increase the overall cost and lead time of high-performance components. Examples are medical devices where surfaces may contact the patient's skin and hence need to be smooth and aerospace components with high fatigue strength requirements where surface roughness could reduce fatigue life. The average surface roughness (Ra) of AM parts can reach high levels greater than 50 μm and maximum distance between the high peaks and the low valleys of more than 300 μm. As such, there is a need for fast, cost effective and selective finishing methods of AM produced components targeted at high-performance industries. In this paper Ti-6Al-4V Grade 23 ELI, popular for medical devices and aerospace parts production, was L-PBF processed to manufacture parts which were subsequently treated via laser polishing. Here in this work, CO2 laser polishing was used for the surface modification of the Ti-6Al-4V produced samples. The most significant processing parameters were optimised to achieve approximately an 80% reduction in the average surface roughness and a 90% reduction in the peak-to-valley distance with a processing time of 0.1 s/mm2 and cost of 0.2 €/cm2. •CO2 laser polishing of additively manufactured Ti-6Al-4V is presented.•Flat and cylindrical samples were successfully polished by using the methodology detailed in this article.•The percent overlap of the laser scanning track was an effective processing parameter to reduce surface roughness.•Double-pass lasing offered a further reduced surface roughness.