Polishing of EB-PBF Ti6Al4V Vertical Surfaces with Semi-Melted Particle Characteristics Realized by Continuous Laser

Electron beam powder bed fusion (EB-PBF) Ti6Al4V often exhibits high vertical surface roughness, limiting its use in high-end applications. In this study, an infrared continuous-wave laser was applied to precisely polish the vertical surface. An orthogonal design identified the optimal condition as 10,400 kW/cm² power density, 800 mm/s scanning speed, and one pass, achieving a minimum Sa of 0.24 μm and a 98.03% reduction compared with the as-built surface. To address the adhered semi-molten particle characteristics of EB-PBF sidewalls, a molten-pool-dynamics-based polishing model was developed and validated, yielding an error as low as 1.24%. Simulations indicate that power density governs the final morphology by controlling molten pool coverage, scanning speed affects polishing efficiency via thermocapillary force, and polishing time influences surface quality by triggering or avoiding melt splashing.