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ABSTRACTElectro-chemical polishing (ECP) was utilized to produce sub-micron surface finish on Inconel 718 parts manufactured by Laser Powder-Bed-Fusion (L-PBF) and extrusion methods. The L-PBF parts had very rough surfaces due to semi-welded powder particles, surface defects, and difference layer steps that were generally not found on surfaces of extruded and machined components. This study compared the results of electro-polishing of these differently manufactured parts under the same conditions. Titanium electrode was used with an acid-based electrolyte to polish both the specimens at different combinations of pulsed current density, duty cycle, and polishing time. Digital 3D optical profiler was used to assess the surface finish, while optical and scanning electron microscopy was utilized to observe the microstructure of polished specimens. At optimal condition, the ECP successfully reduced the surface of L-PBF part from 17 µm to 0.25 µm; further polishing did not improve the surface finish due to different removal rates of micro-leveled pores, cracks, nonconductive phases, and carbide particles in 3D-printed Inconel 718. The microstructure of extruded materials was uniform and free of processing defects, therefore can be polished consistently to 0.20 µm. Over-polishing of extruded material could improve its surface finish, but not for the L-PBF material due to defects and the surrounding micro-strain.
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This content will become publicly available on April 1, 2026
Assessing the Printability of Rene 65 Powder for Repairing Degraded GTD 111 Gas Turbine Blades Using L-DED and L-PBF
Restoring components in the hot gas path of turbine engines after service-induced degradation is crucial for economic efficiency. This study investigates the printability of Rene 65 powder on a degraded first-stage turbine blade using two additive manufacturing techniques: Laser Powder Bed Fusion (L-PBF) and Laser Powder Directed Energy Deposition (L-DED). Deposited material was evaluated using optical microscopy (OM), scanning electron microscopy (SEM), and Electron Backscatter Diffraction (EBSD) to characterize its crystallographic texture, while microhardness testing provided insight into its mechanical properties. Our results show that L-PBF excels at replicating intricate features, such as small cooling holes, and produces a highly texturized microstructure oriented parallel to <001> under optimal parameters (80 W, 400 mm/s, unidirectional scanning), although at a slower pace. In contrast, L-DED offers a versatile, rapid, and cost-effective method for repairing medium to large parts, yielding an equiaxed microstructure and higher as-printed hardness—approaching GTD 111 values due to an aging effect from high heat input. Both processes effectively restored the dimensional integrity of degraded blade tips, paving the way for more sustainable and economical maintenance strategies in the aerospace industry.
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- PAR ID:
- 10591301
- Publisher / Repository:
- MDPI
- Date Published:
- Journal Name:
- Coatings
- Volume:
- 15
- Issue:
- 4
- ISSN:
- 2079-6412
- Page Range / eLocation ID:
- 410
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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