Influence of microstructure and surface topography on material removal by the Hirtisation® process

Journal article, 2024

The Hirtisation® process is an electro-chemical process, wherein the electrolyte can easily access both external and internal surfaces. The process shows promising results in both support structure removal and reduction of surface roughness, and has the potential to solve the productivity and quality trade-off in powder bed fusion–laser beam (PBF-LB) processing. In this study, the role of the microstructure and surface topography on the capability of the Hirtisation® process to lower the PBF-LB produced surface roughness, has been investigated. A detailed microstructure analysis by SEM was used to determine the effect of the Hirtisation® process on removal of sintered powder, the effects on melt pool boundaries and grain boundaries, and thus the final surface quality. The Hirtisation® process significantly reduced surface roughness thanks to the complete removal of sintering powder from the as-built surface. Additionally, preferential material removal was detected along melt pool boundaries, leading to creation of notches of up to 10 µm in depth.