增材制造金属材料复杂结构表面后处理技术研究进展

徐占昭; 王兵; 刘战强; 赵金富; 李亮亮; 宋清华

doi:10.16490/j.cnki.issn.1001-3660.2026.19.014

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表面技术 ›› 2026, Vol. 55 ›› Issue (19) : 156-181. DOI: 10.16490/j.cnki.issn.1001-3660.2026.19.014

表界面强化技术

增材制造金属材料复杂结构表面后处理技术研究进展

徐占昭^1,2,3, 王兵^1,2,3,*, 刘战强^1,3,4, 赵金富^1,2,3, 李亮亮⁵, 宋清华^1,2,3

作者信息 +

Research Progress on Post-processing Technologies for Complex Surfaces of Additively Manufactured Metallic Materials

XU Zhanzhao^1,2,3, WANG Bing^1,2,3,*, LIU Zhanqiang^1,3,4, ZHAO Jinfu^1,2,3, LI Liangliang⁵, SONG Qinghua^1,2,3

Author information +

文章历史 +

摘要

高质量表面加工是保障装备零件工作性能和服役寿命的共性关键技术。增材制造技术能够实现复杂几何结构金属零件制备,但通常伴随高表面粗糙度、微观组织缺陷以及残余拉应力等特征,易导致零件难以满足实际服役需求,通常需在增材制造工艺后进行表面后处理以提高零件表面完整性。本文旨在综述不同后处理技术对增材制造零件表面几何特征、物理冶金特性和力学性能的作用规律,探讨改善零件表面完整性综合技术指标的高效后处理方法。首先,在概括增材制造金属复杂结构表面完整性特征基础上,分析了化学、电化学、磨粒流、激光等四种表面抛光技术原理及其对零件表面几何属性的改善作用,归纳总结了热处理、空化强化、激光冲击强化等表面强化后处理方法对零件表面物理冶金特性和力学性能的改善效果。其次,讨论了单一后处理技术在改善增材制造金属材料复杂结构表面完整性方面的局限性,阐述了复合型表面后处理技术的发展现状及其技术优势和可行性,总结了增材制造金属材料复杂结构表面后处理技术研究存在的问题。最后,针对高质高效表面后处理技术的未来研究方向进行总结与展望。

Abstract

High-quality surface processing is a common and critical technology to ensure the service performance and service life of equipment components. Additive manufacturing (AM) technology enables the fabrication of metal parts with complex geometric structures, however, owing to the intrinsic characteristics of significant temperature gradients, repeated melting of the feedstock, and ultra-rapid cooling rates during the additive manufacturing of metallic materials, the fabricated parts are prone to issues including high surface roughness (with prominent spheroidization phenomena), microstructural defects, and residual tensile stress concentration, which impair the mechanical properties and service performance of the parts, rendering them unable to meet the practical application specifications. Although the surface quality of materials can be optimized to a certain extent by controlling the quality of additively manufactured powder or process parameters, there is a gap from the service requirements of the parts. To ensure the performance of the formed material, surface post-processing is generally required to enhance the surface integrity of the parts. This paper aims to review the influences of different post-processing technologies on the surface geometric characteristics, physical metallurgical properties, and mechanical properties of AM parts, and explore efficient post-processing technologies for improving the comprehensive technical indicators of part surface integrity. Firstly, based on a summary of the surface integrity characteristics of AM metal parts with complex structures, the principles of four surface polishing technologies (including chemical polishing, electrochemical polishing, abrasive flow polishing, and laser polishing) and their effects on improving the surface geometric properties of parts are analyzed. Additionally, the improvement effects of surface strengthening post-processing methods (such as heat treatment, cavitation peening, and laser shock peening) on the surface physical metallurgical properties and mechanical properties of parts are summarized. Secondly, limitations of single post-processing technologies in improving the surface integrity of complex structures of additively manufactured metallic materials are explored, together with their failure to achieve a balanced compromise between the surface integrity of AM metallic materials and processing uniformity. For instance, conventional polishing processes can merely refine surface topography and reduce surface roughness yet fail to mitigate residual tensile stress or optimize microstructure. Thus, it is imperative to explore the implementation of synergistic coupling of two or more post-processing technologies to realize the comprehensive enhancement of surface integrity for complex structures of AM metallic materials. This section elaborates on the development status, technical advantages, and feasibility of two categories of hybrid post-processing technologies, namely sequential hybrid and simultaneous hybrid post-processing. A particular focus is placed on the cavitation peening- electrochemical polishing hybrid post-processing method, hydrodynamic cavitation abrasive flow machining and ultrasonic cavitation abrasive machining technology. Finally, the existing problems in the research of post-processing technologies for complex surfaces of additively manufactured metallic materials are summarized, which are limited to experimental methods and empirical optimization of process parameters, with deficiencies in theoretical modeling, processing mechanisms, and process applications. The future research directions for high-quality and high-efficiency surface post-processing technologies are summarized and prospected, with focus on the physical mechanisms of multi-energy field on surface integrity evolution, the uniformity and stability of complex structure surface improvement, and dynamic monitoring and parameter adaptive adjustment in the surface post-processing process.

导出引用

徐占昭, 王兵, 刘战强, 赵金富, 李亮亮, 宋清华. 增材制造金属材料复杂结构表面后处理技术研究进展[J]. 表面技术. 2026, 55(19): 156-181

XU Zhanzhao, WANG Bing, LIU Zhanqiang, ZHAO Jinfu, LI Liangliang, SONG Qinghua. Research Progress on Post-processing Technologies for Complex Surfaces of Additively Manufactured Metallic Materials[J]. Surface Technology. 2026, 55(19): 156-181

中图分类号： TG178

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