Surface finishing of 3D-printed Ti-6Al-4 V alloy by electrolyte plasma polishing: Process optimization and microstructure

The electrolyte plasma polishing (EPP) technology is proposed to remove the unmelted powder particles and oxide film for high-quality surface finishing of 3D-printed Ti-6Al-4 V alloy. An orthogonal experiment is conducted to investigate multiple factors that contribute to the surface quality of the alloy during the polishing process. The optimal parameters determined for the EPP process are a voltage of 300 V, a polishing time of 12 min, a polishing depth of 12 cm, and a temperature of 75 degrees C. Based on the extent of the effect, the factors influencing surface roughness were ranked: voltage > time > depth > temperature. The surface crest and trough area of the alloy is substantially reduced after polishing, while the average roughness experienced a reduction of 76 %. The improvement in surface quality is attributed to the corrosion of the oxide layer by F ions in the electrolytic solution, and the melting of surface protrusions due to the impact of high-energy electrons under high-temperature and high-pressure conditions during plasma discharge. Additionally, the surface hardness of the material decreases slightly, but its corrosion resistance and hydrophobicity are enhanced, and the calibration rate of the EBSD sample can reach 92.51 %, demonstrating that it is an excellent surface finishing technique. Hence, EPP is a promising approach for smoothening 3D-printed metals, especially for alloy parts with complex geometry and porous structure.