A hybrid post-processing method for improving the surface quality of additively manufactured metal parts

Abstract A hybrid post-processing method that synergistically combines cavitation peening and electrochemical polishing to achieve superior surface quality of solid and lattice structured additively manufactured (AM) metal parts is analysed. The method enables surface strengthening of AM parts through plastic deformation caused by cavitation while simultaneously improving the surface finish through electrochemical dissolution of surface asperities. Compared to sequential processing, the hybrid process produces higher microhardness and comparable surface roughness in a single step. Results show that coupling of the physical-chemical effects accompanying cavitation and electrochemical reaction can enhance the cavitation intensity and dissolution efficiency in hybrid processing.