Hybrid manufacturing: influence of material properties during micro milling of different additively manufactured AISI 316L

Abstract Additive manufacturing (AM) enables the production of components with a high degree of individualization at constant manufacturing effort, which is why additive manufacturing is increasingly applied in industrial processes. However, additively produced surfaces do not meet the requirements for functional surfaces, which is why subsequent machining is mandatory for most of AM-workpieces. Further, the performance of many functional surfaces can be enhanced by microstructuring. The combination of both AM and subtractive processes is referred to as hybrid manufacturing. In this paper, the hybrid manufacturing of AISI 316L is investigated. The two AM technologies laser-based powder bed fusion (L-PBF) and high-speed laser directed energy deposition (HS L-DED) are used to produce workpieces which are subsequently machined by micro milling (tool diameter d = 100 µm). The machining results were evaluated based on tool wear, burr formation, process forces and the generated topography. Those indicated differences in the machinability of materials produced by L-PBF and HS L-DED which were attributed to different microstructural properties.