Ultrafast laser-based post-processing of parts produced by additive manufacturing

Laser Additive Manufacturing (LAM) is a near-net shape manufacturing approach, meaning that the resulting part geometry can be considerably affected by heat-induced distortions, solidified melt droplets, partially fused powders, and surface modifications induced by the laser tool motion and processing strategy. High-repetition rate femtosecond laser radiation was utilized to improve surface quality of metal parts manufactured by laser additive techniques. Different laser scanning approaches were utilized to increase the ablation efficiency and to improve the surface finish. Processing of 3D-shaped parts made of Ni- and Ti-base superalloys resulted in the reduction of the average surface roughness to a few microns. This approach can be used to post-process parts made of thermally and mechanically sensitive materials, and to attain complex designed shapes with micrometer precision.