王志,董世运,闫世兴,刘晓亭,李立伟,夏丹.增材制造金属零件超快激光抛光技术研究进展[J].表面技术,2025,54(7):19-33.
WANG Zhi,DONG Shiyun,YAN Shixing,LIU Xiaoting,LI Liwei,XIA Dan.Advances in the Research of Ultrafast Laser Polishing Technologies for Additive Manufacturing Metal Parts[J].Surface Technology,2025,54(7):19-33 |
| 增材制造金属零件超快激光抛光技术研究进展 |
| Advances in the Research of Ultrafast Laser Polishing Technologies for Additive Manufacturing Metal Parts |
| 投稿时间：2024-09-11 修订日期：2025-01-17 |
| DOI：10.16490/j.cnki.issn.1001-3660.2025.07.002 |
| 中文关键词: 增材制造 表面后处理 激光技术 超快激光 激光抛光 |
| 英文关键词:additive manufacturing surface post-treatment laser technique ultrafast laser laser polishing |
| 基金项目:国家重点研发计划(2023YFB4606601) |
| 作者 | 单位 |
| 王志 | 陆军装甲兵学院 装备再制造技术国防科技重点实验室，北京 100072 |
| 董世运 | 陆军装甲兵学院 装备再制造技术国防科技重点实验室，北京 100072 |
| 闫世兴 | 陆军装甲兵学院 装备再制造技术国防科技重点实验室，北京 100072 |
| 刘晓亭 | 陆军装甲兵学院 装备再制造技术国防科技重点实验室，北京 100072 |
| 李立伟 | 江苏师范大学 物理与电子工程学院，江苏 徐州 221116 |
| 夏丹 | 陆军装甲兵学院 装备再制造技术国防科技重点实验室，北京 100072 |
|
| Author | Institution |
| WANG Zhi | National Key Laboratory for Remanufacturing, Army Academy of Armored Forces, Beijing 100072, China |
| DONG Shiyun | National Key Laboratory for Remanufacturing, Army Academy of Armored Forces, Beijing 100072, China |
| YAN Shixing | National Key Laboratory for Remanufacturing, Army Academy of Armored Forces, Beijing 100072, China |
| LIU Xiaoting | National Key Laboratory for Remanufacturing, Army Academy of Armored Forces, Beijing 100072, China |
| LI Liwei | School of Physics and Electronic Engineering, Jiangsu Normal University, Jiangsu Xuzhou 221116, China |
| XIA Dan | National Key Laboratory for Remanufacturing, Army Academy of Armored Forces, Beijing 100072, China |
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| 中文摘要: |
| 增材制造(AM)具有加工步骤简单、可原位制造、可定制零件等突出特点，在航空航天、生物医疗、汽车制造等领域获得了广泛认可。但是增材制造的金属零件表面粗糙度较高、成形尺寸精度较差，需要进行表面抛光才能使用，这限制了该技术优势的发挥。如何突破这一技术瓶颈成为当前的研究热点，原位抛光是其中一个分支。基于此，综述了超快激光抛光增材制造金属零件的新进展。概述了金属增材制造的主要工艺、零件表面的主要缺陷以及主要的抛光技术，总结归纳了传统激光抛光的不足和超快激光抛光的加工优势;重点综述了金属的超快激光抛光发展、超快激光抛光机制、金属AM零件的超快激光抛光发展现状、设备集成发展等方面的内容;最后指出了超快激光抛光增材制造零件及其设备的发展方向，对该技术将得到广泛应用的前景进行了展望。本文填补了在增材制造金属零件表面超快激光抛光方面的综述空白。 |
| 英文摘要: |
| Recently, advancements in artificial intelligence have brought new opportunities to additive manufacturing (also known as 3D printing), especially in digital model construction, process path optimization, and human-machine interaction. This technology offers several advantages, such as fabricating complex structures that are unattainable with traditional manufacturing methods, personalized customization, shortening development cycles, simplifying processes, enabling in-situ manufacturing, and reducing material waste. Therefore, it engenders the transformation and upgrading of the manufacturing industry. Components produced by metal additive manufacturing have been widely applied in fields such as aerospace, biomedicine and automotive industry. However, these surfaces have a high roughness, which affects their function, including appearance, assembly, and service performance. As a result, it is necessary to polish the surface to reduce constraints on the widespread application of the technology. In order to overcome this obstacle, the research focuses on enhancing the accuracy of additive manufacturing and reducing its roughness, as well as implementing in-situ polishing post-fabrication. Ultrafast laser polishing technology can effectively improve surface quality, which broadens the industrial application scope of additive manufacturing technology. Ultrafast laser polishing technology retains its traditional advantages, which include characteristics such as flexibility, non-contact processing, intelligence, in-situ processing, and environmental friendliness. It can achieve high precision and cold processing and is capable of handling almost all known materials. Currently, widely adopted methods such as abrasive flow and electrochemistry have their own advantages, but they cannot be compared with ultrafast laser polishing technology in terms of in-situ processing and integration with laser additive manufacturing equipment. Traditional laser polishing methods, primarily based on hot working, long pulse and continuous laser polishing may lead to remelted surfaces, large heat-affected zones, and microcracks. Challenges include difficulties in polishing thin-walled, microstructured, and complex geometries (e.g., grids and foams), suboptimal polishing of multilayer, thermally sensitive, brittle materials, and inefficiency in polishing hard and refractory materials. Ultrafast laser polishing technology can effectively overcome these challenges. It is a short time since ultrafast laser polishing technology has been applied in the field of additive manufacturing for metal parts. This technology integrates ultrafast laser processing with additive manufacturing techniques. Meanwhile, it is primarily based on the rapidly developing cold polishing mechanism. Experimental studies and microscopic analyses have confirmed that the technology achieves small heat-affected zones and high-precision polishing. According to the relative angle between the polishing beam and the processed surface, the technology can be divided into vertical incidence and grazing incidence. Based on the number of repetitions in the processing, the technology can be categorized into single-pass and multi-pass polishing strategies. At present, this technology has refined the surface roughness Ra value from tens of micrometers or several micrometers down to the nanometer level. However, there is little literature available on roughness values less than 0.1 microns. Compared to traditional laser polishing technology, ultrafast laser polishing is in a stage of rapid development, and there is still potential to improve the quality of the polishing. The concept of integrating 3D printing with ultrafast laser polishing was proposed before 2018. In 2018, Ghosh and Worts independently proposed their respective design schemes for this integration. Ghosh also achieved a polishing effect with an average sidewall roughness of (4.7±1) mm and a sidewall taper angle of approximately 3°±1° through experimentation. Bouet further advanced this technology in 2019, developing an integrated device capable of directly manufacturing Ti-6Al-4V parts with biologically functional surfaces, eliminating subsequent processing steps. Studies have also shown that during additive manufacturing (AM), in-situ ultrafast laser polishing can increase part density and reduce porosity, thereby improving the overall quality. The emergence of ultrafast laser 3D printing equipment opens up a new direction for integrated printing and polishing systems that utilize a single laser source. This approach offers advantages in miniaturization and functional integration compared to devices equipped with dual laser sources. This review delves into the application and addresses the challenges of ultrafast laser polishing technology within the domain of metal additive manufacturing. Although this technology is considered as an effective method for improving the quality of surface treatment, it still encounters technical challenges in reducing surface roughness and increasing polishing efficiency, especially when processing internal surfaces and complex-shaped components. To overcome these challenges, the ongoing research and development of ultrafast laser polishing equipment increasingly focuses on miniaturization, lightweight design, multifunctionality, and intelligent operation. These technological advancements are of great significance for meeting the manufacturing and repair needs in extreme environments within industries such as aerospace and energy. With the increasing demand for high surface quality in additive manufacturing products such as biomedical implants, automotive parts, industrial molds, and everyday commodities, the application of ultrafast laser polishing technology is becoming increasingly critical. Consequently, it is predictable that as technology continues to advance, ultrafast laser polishing will play an increasingly prominent role in the post-processing stage of additive manufacturing. This research bridges the gaps in comprehensive reviews regarding ultrafast laser polishing for the surfaces of metal components fabricated through additive manufacturing. |
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