Surface Optimization of Additively Manufactured (AM) Stainless Steel Components Using Combined Chemical and Electrochemical Post-Processing
Source abstract
Abstract
The design and production of goods have been completely transformed by additive manufacturing (AM), which makes it possible to create components with intricate and complex geometries that were previously impossible or impractical to produce. However, current technologies continue to produce coarse-surfaced metal components that typically exhibit fatigue properties, resulting in component failure and unfavorable friction coefficients on the printed part. Therefore, to improve the surface quality of the fabricated parts, post-processing of AM-created components is required. With emphasis on electroless nickel plating, ChemPolishing (CP), and ElectroPolishing (EP), this study investigates post-processing methods for stainless steel that is additively manufactured (AM). The rough surfaces created by additive manufacturing (AM) restrict direct use. While ElectroPolishing (EP) achieves high material removal rates but may not be consistent, ChemPolishing (CP) offers uniform smoothening. Nickel plating enhances additive manufacturing (AM) products’ resistance to wear and scratches and corrosion protection. To optimize nickel deposition, medium (6%–9%) and high (10%–13%) phosphorus nickel was tested using the L9 Taguchi design of experiments (DOE). Mechanical properties, including scratch resistance and adhesion, were evaluated using the TABER 5900 reciprocating (Taber Industries, North Tonawanda, NY, USA) abraser apparatus, a 5 N scratch test, and ASTM B-733 thermal shock method. Surface analysis was performed with the KEYENCE VHX-7000 microscope (Keyence Corporation, Itasca, IL, USA), and chemical composition before and after nickel deposition was assessed via the ThermoFisher Phenom XL scanning electron microscope (SEM, Thermo Fisher Scientific, Waltham, MA, USA) Optimal processing conditions, determined using Qualitek-4 software, Version 20.1.0 revealed improvements in both surface finish and mechanical robustness. This comprehensive analysis underscores the potential of nickel-coated additive manufacturing (AM) parts for enhanced performance, offering a pathway to more durable and efficient additive manufacturing (AM) applications.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing and 3D Printing Technologies · Additive Manufacturing Materials and Processes · Advanced Machining and Optimization Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Mechanical Engineering, University of the District of Columbia, Washington, DC 20008, USA
Honeywell Federal Manufacturing & Technologies, LLC., Kansas City Nuclear Security Campus, Kansas City, MO 64147, USA
Funding
National Science Foundation-CREST Award · Department of Energy/National Nuclear Security Agency · NASA MUREP Institutional Research Opportunity Grant · Honeywell Federal Manufacturing & Technologies, LLC.
References (40)
Show source-provided references
1. Annular laser beam based direct metal deposition10.1016/j.procir.2018.08.099 ↗
2. Microstructure, Tribological Properties and Corrosion Behaviour of Additively Manufactured 17-4PH Stainless Steel: Effects of Scanning Pattern, Build Orientation, and Single vs. Double scan10.1016/j.mtcomm.2020.101535 ↗
3. Surface roughness profile and its effect on coating adhesion and corrosion protection: A review10.1016/j.porgcoat.2020.105847 ↗
4. Metal additive-manufacturing process and residual stress modeling10.1186/s40192-016-0047-2 ↗
5. Reducing the roughness of internal surface of an additive manufacturing produced 316 steel component by chempolishing and electropolishing
6. The effect of surface roughness on the adhesion of elastic plates with application to biological systems10.1063/1.1621854 ↗
7. Surface ‘Roughness’ Effect on Marine Immersion Corrosion of Mild Steel10.5006/1.3287847 ↗
8. Effect of surface roughness on low-cycle fatigue behavior of type 304 stainless steel10.1007/BF02642305 ↗
9. Electropolishing of medical-grade stainless steel in preparation for surface nano-texturing10.1007/s10008-011-1539-9 ↗
10. Electrochemical polishing as a 316L stainless steel surface treatment method: Towards the improvement of biocompatibility10.1016/j.corsci.2014.06.010 ↗
11. Electropolishing and electropolishing-related allowances for IN625 alloy components fabricated by laser powder-bed fusion10.1007/s00170-017-0546-0 ↗
12. Comparison of electropolishing behaviours of TSC, ALM and cast 316L stainless steel in H3PO4/H2SO410.1016/j.surfin.2017.01.008 ↗
13. Electropolishing Behavior of Additive Layer Manufacturing 316L Stainless Steel in Deep Eutectic Solvents10.1149/07711.1199ecst ↗
14. Mahmoud, M.M.M. (2022). Surface Finishing Treatment After Additive Manufacturing Processes Selective Lasr Melting and Selective Laser Sintering for Stainless Steel Parts. [Master’s Thesis, Politecnico di Milano].
15. (2025, September 10). 8 Metal Surface Finishing Treatment Processes|Keller Technology. Keller Technology Corporation. [Online]. Available online: https://www.kellertechnology.com/blog/8-common-types-of-surface-treatments-for-metal-parts/.
16. Polypoid Atypical Spitz Tumor With a Fibrosclerotic Stroma, CLIP2-BRAF Fusion, and Homozygous Loss of 9p2110.1097/DAD.0000000000001502 ↗
17. Microstructural characterization, applications and process study of various additive manufacturing process: A review10.1016/j.matpr.2020.01.048 ↗
18. (2025, September 10). What is Electropolishing? How Does Electropolishing Work? Best Technology. [Online]. Available online: https://www.besttechnologyinc.com/electropolishing-equipment/how-does-electropolishing-work/.
19. (2025, September 10). Electropolishing: Polishing with Electricity—Allegheny Surface Technology. [Online]. Available online: https://alleghenysurface.com/whitepaper/electropolishing-polishing-with-electricity/.
20. Electropolishing effects on corrosion behavior of 304 stainless steel in high temperature, hydrogenated water10.1016/j.corsci.2008.06.032 ↗
21. Demisse, W., Mutunga, E., Klein, K., Rice, L., and Tyagi, P. (2021, January 1–5). Surface Finishing and Electroless Nickel Plating of Additively Manufactured (AM) Metal Components. Proceedings of the ASME International Mechanical Engineering Congress and Exposition, Online.10.1115/IMECE2021-71882 ↗
22. Alternating chempolishing and electropolishing for interior and exterior surface finishing of additively manufactured (AM) metal components10.1007/s00170-022-09857-y ↗
23. Dillard, J., Grizzle, A., Demisse, W., Tyagi, P., Rice, L., and Benton, C. (2020, January 16–19). Effect of Altering the Sequence of Chempolishing and Electropolishing on Surface Properties of Additively Manufactured (AM) 316 Steel Components. Proceedings of the ASME International Mechanical Engineering Congress and Exposition, Online.10.1115/1.0004300V ↗
24. Influence of the surface state on the corrosion behavior of the 316 L stainless steel manufactured by laser powder bed fusion10.1016/j.corsci.2022.110550 ↗
25. Nickel plating on steel by chemical reduction10.6028/jres.037.019 ↗
26. A low temperature electroless nickel plating chemistry10.1016/j.surfcoat.2019.05.019 ↗
27. Crystallisation Kinetics and Phase Transformation Behaviour of Electroless Nickel-Phosphorus Deposits with High Phosphorous Content10.1016/S0925-8388(01)01798-4 ↗
28. Electroless Nickel Plating—A Review10.1007/s12633-015-9367-7 ↗
29. Electroless nickel plating of electropolished and chempolished Additively Manufactured (AM) steel components in various surface orientations10.1007/s00170-024-14217-z ↗
30. (2025, September 11). The Ultimate Guide to Gas Atomizers for Metal Powder Production|Additive Manufacturing Material. [Online]. Available online: https://am-material.com/aluminum-based-alloy-powder/gas-atomizers-for-metal-powder-production/.
31. Engineering Department (2025, September 11). What Is Passivation and How Does It Work—LEADRP—Rapid Prototyping and Manufacturing Service. [Online]. Available online: https://leadrp.net/blog/what-is-passivation-and-how-does-it-work/.
32. (2025, September 11). Optimizing Metal Powders for Additive Manufacturing. [Online]. Available online: https://www.additivemanufacturing.media/articles/optimizing-metal-powders-for-additive-manufacturing-exploring-the-impact-of-particle-morphology-and-powder-flowability.
33. (2014). Standard Guide for Cleaning Metals Prior to Electroplating (Standard No. ASTM B322-99 (Reapproved 2014)).
34. Electroless Nickel Plating Services (2025, September 11). Valence Surface Technologies. [Online]. Available online: https://live-valence-surface-tech.pantheonsite.io/services/plating/electroless-nickel-plating/.
35. Sanchez, P., Waqar, Z., and Tyagi, P. (November, January 30). Application of Nickel Deposition on Electropolishing (EP), Chempolishing (CP), and As-Built Additively Manufactured (AM) Metal Components. Proceedings of the ASME International Mechanical Engineering Congress and Exposition, Columbus, OH, USA.
36. Kiguchi, M. (1996). Surface Modification and Activation of Wood. Chemical Modification of Lignocellulosic Materials, Routledge.
37. Surface roughness measuring in case of electro-erosion processed work pieces10.1088/1757-899X/568/1/012023 ↗
38. (2017). Standard Test Method for Scratch Hardness of Materials Using a Diamond Stylus (Standard No. ASTM G171-03(2017)). Available online: https://store.astm.org/g0171-03r17.html.
39. (1997). Standard Specification for Autocatalytic (Electroless) Nickel-Phosphorus Coatings on Metal (Standard No. ASTM B 733–97). Available online: https://store.astm.org/b0733-22.html.
40. Sanchez, P., Tyagi, P., and Shetty, D. (2025, January 16–20). Exploring Electroless Nickel Plating Applications on Additively Manufactured Metal Components: As-Built, ChemPolished (CP), and Electropolished (EP) Surfaces. Proceedings of the ASME 2025 International Mechanical Engineering Congress and Exposition (IMECE2025), Memphis, TN, USA.