Comparative analysis of machining and electropolishing for surface quality improvement of shape memory nitinol samples additively manufactured by laser powder bed fusion
Nickel-titanium (NiTi) or nitinol alloys exhibit high corrosion resistance, mechanical strength, biocompatibility, and smart properties, rendering them ideal materials for active biomedical devices. Traditional manufacturing techniques struggle with these alloys, prompting the adoption of Laser Powd...
Saved in:
| Main Authors: | , , , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-02-01
|
| Series: | Additive Manufacturing Letters |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2772369024000690 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1841533231966453760 |
|---|---|
| author | Rodrigo Zapata Martínez Shohom Bose-Bandyopadhyay Alan Burl Óscar Contreras-Almengor Carlos Aguilar Vega Kyle Saleeby Thomas Kurfess Andrés Díaz Lantada Jon Molina-Aldareguia |
| author_facet | Rodrigo Zapata Martínez Shohom Bose-Bandyopadhyay Alan Burl Óscar Contreras-Almengor Carlos Aguilar Vega Kyle Saleeby Thomas Kurfess Andrés Díaz Lantada Jon Molina-Aldareguia |
| author_sort | Rodrigo Zapata Martínez |
| collection | DOAJ |
| description | Nickel-titanium (NiTi) or nitinol alloys exhibit high corrosion resistance, mechanical strength, biocompatibility, and smart properties, rendering them ideal materials for active biomedical devices. Traditional manufacturing techniques struggle with these alloys, prompting the adoption of Laser Powder Bed Fusion (L-PBF) as a viable alternative for producing geometrically challenging features. However, L-PBF inherently introduces geometric inconsistencies and surface defects, necessitating post-processing. Electropolishing and chemical etching, while effective for surface smoothing, result in non-conformal material removal, potentially altering the designed geometry. This study examines the use of machining as a post-processing method to achieve uniform material removal and maintain geometric fidelity. Planar spring-shaped actuators were fabricated via L-PBF and subsequently machined to their final geometry using a Computer Numerical Controlled (CNC) system. The actuators were assessed for geometric accuracy and shape memory properties. Machining of the actuators lead to a near homogeneous thickness of 300 µm in all cases, whereas the electropolished + chemically etched samples varied dramatically from <50 µm to over 400 µm in thickness. The findings demonstrate that CNC machining effectively enhances the geometric precision of L-PBF-manufactured NiTi components, while preserving shape memory characteristics. This research underscores the potential of integrating L-PBF with CNC machining to improve the precision and functionality of NiTi-based biomedical devices. |
| format | Article |
| id | doaj-art-5305366f80854693b40fa08367905c96 |
| institution | Kabale University |
| issn | 2772-3690 |
| language | English |
| publishDate | 2025-02-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Additive Manufacturing Letters |
| spelling | doaj-art-5305366f80854693b40fa08367905c962025-01-17T04:52:27ZengElsevierAdditive Manufacturing Letters2772-36902025-02-0112100261Comparative analysis of machining and electropolishing for surface quality improvement of shape memory nitinol samples additively manufactured by laser powder bed fusionRodrigo Zapata Martínez0Shohom Bose-Bandyopadhyay1Alan Burl2Óscar Contreras-Almengor3Carlos Aguilar Vega4Kyle Saleeby5Thomas Kurfess6Andrés Díaz Lantada7Jon Molina-Aldareguia8Department of Mechanical Engineering, ETSI Industriales, Universidad Politécnica de Madrid, Madrid, Spain; Corresponding authors.George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, United StatesGeorge W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, United StatesIMDEA Materials Institute, Tecnogetafe, Getafe, Spain; Carlos III University, Leganés, SpainDepartment of Mechanical Engineering, ETSI Industriales, Universidad Politécnica de Madrid, Madrid, SpainGeorge W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, United States; Georgia Tech Manufacturing Institute, Georgia Institute of Technology, United StatesGeorge W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, United States; Georgia Tech Manufacturing Institute, Georgia Institute of Technology, United StatesDepartment of Mechanical Engineering, ETSI Industriales, Universidad Politécnica de Madrid, Madrid, Spain; Corresponding authors.Department of Mechanical Engineering, ETSI Industriales, Universidad Politécnica de Madrid, Madrid, Spain; IMDEA Materials Institute, Tecnogetafe, Getafe, SpainNickel-titanium (NiTi) or nitinol alloys exhibit high corrosion resistance, mechanical strength, biocompatibility, and smart properties, rendering them ideal materials for active biomedical devices. Traditional manufacturing techniques struggle with these alloys, prompting the adoption of Laser Powder Bed Fusion (L-PBF) as a viable alternative for producing geometrically challenging features. However, L-PBF inherently introduces geometric inconsistencies and surface defects, necessitating post-processing. Electropolishing and chemical etching, while effective for surface smoothing, result in non-conformal material removal, potentially altering the designed geometry. This study examines the use of machining as a post-processing method to achieve uniform material removal and maintain geometric fidelity. Planar spring-shaped actuators were fabricated via L-PBF and subsequently machined to their final geometry using a Computer Numerical Controlled (CNC) system. The actuators were assessed for geometric accuracy and shape memory properties. Machining of the actuators lead to a near homogeneous thickness of 300 µm in all cases, whereas the electropolished + chemically etched samples varied dramatically from <50 µm to over 400 µm in thickness. The findings demonstrate that CNC machining effectively enhances the geometric precision of L-PBF-manufactured NiTi components, while preserving shape memory characteristics. This research underscores the potential of integrating L-PBF with CNC machining to improve the precision and functionality of NiTi-based biomedical devices.http://www.sciencedirect.com/science/article/pii/S2772369024000690Additive manufacturingShape-memory alloysMicromachiningElectropolishingSurface quality |
| spellingShingle | Rodrigo Zapata Martínez Shohom Bose-Bandyopadhyay Alan Burl Óscar Contreras-Almengor Carlos Aguilar Vega Kyle Saleeby Thomas Kurfess Andrés Díaz Lantada Jon Molina-Aldareguia Comparative analysis of machining and electropolishing for surface quality improvement of shape memory nitinol samples additively manufactured by laser powder bed fusion Additive Manufacturing Letters Additive manufacturing Shape-memory alloys Micromachining Electropolishing Surface quality |
| title | Comparative analysis of machining and electropolishing for surface quality improvement of shape memory nitinol samples additively manufactured by laser powder bed fusion |
| title_full | Comparative analysis of machining and electropolishing for surface quality improvement of shape memory nitinol samples additively manufactured by laser powder bed fusion |
| title_fullStr | Comparative analysis of machining and electropolishing for surface quality improvement of shape memory nitinol samples additively manufactured by laser powder bed fusion |
| title_full_unstemmed | Comparative analysis of machining and electropolishing for surface quality improvement of shape memory nitinol samples additively manufactured by laser powder bed fusion |
| title_short | Comparative analysis of machining and electropolishing for surface quality improvement of shape memory nitinol samples additively manufactured by laser powder bed fusion |
| title_sort | comparative analysis of machining and electropolishing for surface quality improvement of shape memory nitinol samples additively manufactured by laser powder bed fusion |
| topic | Additive manufacturing Shape-memory alloys Micromachining Electropolishing Surface quality |
| url | http://www.sciencedirect.com/science/article/pii/S2772369024000690 |
| work_keys_str_mv | AT rodrigozapatamartinez comparativeanalysisofmachiningandelectropolishingforsurfacequalityimprovementofshapememorynitinolsamplesadditivelymanufacturedbylaserpowderbedfusion AT shohombosebandyopadhyay comparativeanalysisofmachiningandelectropolishingforsurfacequalityimprovementofshapememorynitinolsamplesadditivelymanufacturedbylaserpowderbedfusion AT alanburl comparativeanalysisofmachiningandelectropolishingforsurfacequalityimprovementofshapememorynitinolsamplesadditivelymanufacturedbylaserpowderbedfusion AT oscarcontrerasalmengor comparativeanalysisofmachiningandelectropolishingforsurfacequalityimprovementofshapememorynitinolsamplesadditivelymanufacturedbylaserpowderbedfusion AT carlosaguilarvega comparativeanalysisofmachiningandelectropolishingforsurfacequalityimprovementofshapememorynitinolsamplesadditivelymanufacturedbylaserpowderbedfusion AT kylesaleeby comparativeanalysisofmachiningandelectropolishingforsurfacequalityimprovementofshapememorynitinolsamplesadditivelymanufacturedbylaserpowderbedfusion AT thomaskurfess comparativeanalysisofmachiningandelectropolishingforsurfacequalityimprovementofshapememorynitinolsamplesadditivelymanufacturedbylaserpowderbedfusion AT andresdiazlantada comparativeanalysisofmachiningandelectropolishingforsurfacequalityimprovementofshapememorynitinolsamplesadditivelymanufacturedbylaserpowderbedfusion AT jonmolinaaldareguia comparativeanalysisofmachiningandelectropolishingforsurfacequalityimprovementofshapememorynitinolsamplesadditivelymanufacturedbylaserpowderbedfusion |