Enhancing surface integrity of additively manufactured Inconel 718 through numerical modeling of hydrostatic ball burnishing parameters using TOPSIS and ANOVA

Abstract Surface enhancement of laser powder bed fusion components is pivotal for their suitability in end-use applications. Hydrostatic ball burnishing, a mechanical surface hardening technique, induces compressive residual stress on the surface by the application of hydraulic force resulting in improved fatigue life of the material. This present study focuses on determining the optimum burnishing parameter combinations for better surface integrity (roughness, hardness, and residual stress) utilizing ANOVA and TOPSIS analysis. The cumulative performance score of the TOPSIS analysis states that the best parameter combination for Inconel 718 is found to be 300 bar pressure, 0.2 mm burnishing width, and feed 800 mm min −1 . The adjusted R 2 values of the ANOVA model for all three responses are 0.96, 0.93, and 0.94, confirming their close agreement with experimental results. With optimum parameters, the roughness decreased from 2.217 μm to 0.305 μm, Microhardness increased from 318 9HV to 475 9HV and residual stress was converted from tensile 216 MPa to Compressive −54 MPa demonstrating the significance of this process on surface enhancement.