Enhancement of surface characteristics of additively manufactured -TiAl and IN939 alloys after laser shock processing

The enhancement in laser technology opened up new methods such as additive manufacturing (AM) of metals. While AM offers high design flexibility and reduced material usage, it can also produce problematic parts due to poor surface quality. A variety of post-processing techniques are available to address the drawbacks associated with the surface properties of AM. Laser Shock Processing (LSP) is one of the unique methods that induces compressive residual stress (CRS) on the surface and subsurface by creating severe plastic deformation. In this study, two critical aerospace alloys (gamma-TiAl and IN939) were manufactured through two different methods called Powder Bed Fusion with Electron Beam (PBF-EB) and Powder Bed Fusion with Laser Beam (PBF-LB). Subsequently, AM samples were investigated to observe single layer LSP effects on the surface. The results of the laser peening process were determined by residual stress, microhardness and surface roughness measurements. The residual stress profiles showed that LSP significantly induces CRS on the surfaces of AM alloys. For the gamma-TiAl and IN939 samples, the maximum values of CRS and depth of CRS were-460 MPa/1000 mu m and-516 MPa/700 mu m, respectively. Similarly, the microhardness of the materials was increased by 44.4 % for gamma-TiAl and 18.2 % for IN939 by laser post-processing. In addition, a comparison of the roughness of the unground and ground AM samples was carried out. Depending on the surface condition of the AM samples, LSP had different outcomes. For example, the extreme roughness of the AM samples was partially reduced by the thermal effects of the high-energy laser shots. When comparing the roughness values in terms of Ra and Rz, there were decreases in the range of 14.7-21.3 % and 3.34-39.3 % for unground IN939 samples. However, for unground gamma-TiAl samples, depending on the direction of measurement, roughness variations were observed as a 0.99 % decrease -5.3 % increase for Ra and a 2.2 % decrease -14.2 % increase for Rz. The roughness values for ground samples of both alloys were drastically increased, varying between 42.1 % and 7x increase. Sa values were recorded on unground AM samples. For IN939 and gamma-TiAl samples these values decreased by 8.41 % and 15.8 % respectively.