Surface Quality Enhancement of SLM-Fabricated Ti-6Al-4V via Top-Hat Laser Polishing: Melt Pool Dynamics and Microstructural Evolution

Ti-6Al-4V parts fabricated via selective laser melting (SLM) often exhibit severe surface irregularities that limit their direct engineering application. This study proposes a top-hat beam laser polishing method to improve surface quality. The results show that surface roughness (Sa) is reduced to 0.48 μm, a 95.3% decrease from the as-built condition. The uniform energy distribution of the top-hat beam stabilizes melt pool behavior, enabling effective surface leveling through valley filling and lateral melt flow. In contrast, Gaussian beam polishing induces strong Marangoni convection and wake effects, resulting in higher residual roughness. Microstructural analysis indicates an increased fraction of equiaxed α grains and a β-phase content of ~6% after top-hat polishing. The heat-affected zone likely exhibits a subcritical heat-treatment-like effect, promoting fine secondary α precipitation. Additionally, localized stresses induced by steep thermal gradients during SLM are effectively relieved. Overall, top-hat laser polishing is a promising post-processing technique for enhancing the surface quality of Ti-6Al-4V components.