Coupling additive manufacturing (AM) with interlayer peening introduces bulk anisotropic properties within a build across several centimeters. Current methods to map high resolution anisotropy and heterogeneity are either destructive or have a limited penetration depth using a non-destructive method. An alternative pseudo-nondestructive method to map high resolution anisotropy and heterogeneity is through energy consumption during milling. Previous research has shown energy consumption during milling correlates with surface integrity. Since surface milling of additively manufactured parts is often required for post-processing to improve dimensional accuracy, an opportunity is available to use surface milling as an alternative method to measure mechanical properties and build quality. The variation of energy consumption during the machining of additive parts, as well as hybrid AM parts, is poorly understood. In this study, the use of net cutting specific energy was proposed as a suitable metric for measuring mechanical properties after interlayer ultrasonic peening of 316 stainless steel. Energy consumption was mapped throughout half of a cuboidal build volume. Results indicated the variation of net cutting specific energy increased further away from the surface and was higher for hybrid AM compared to as-printed and wrought. The average lateral and layer variation of the net cutting specific energy for printed samples was 81% higher than the control, which indicated a significantly higher degree of heterogeneity. Further, it was found that energy consumption was an effective process signature exhibiting strong correlations with microhardness. Anisotropy based on residual strains were measured using net cutting specific energy and validated by hole drilling. The proposed technique contributes to filling part of the measure gap in hybrid additive manufacturing and capitalizes on the pre-existing need for machining of AM parts to achieve both goals of surface finish and quality assessment in one milling operation.

将增材制造 (AM) 与夹层喷丸相结合，可以在几厘米的构建中引入整体各向异性特性。当前用于绘制高分辨率各向异性和异质性的方法要么具有破坏性，要么使用非破坏性方法具有有限的穿透深度。另一种用于绘制高分辨率各向异性和异质性的伪无损方法是通过铣削过程中的能源消耗。先前的研究表明，铣削过程中的能耗与表面完整性有关。由于后处理通常需要对增材制造零件进行表面铣削以提高尺寸精度，因此有机会使用表面铣削作为测量机械性能和构建质量的替代方法。对增材零件以及混合增材制造零件加工过程中能源消耗的变化知之甚少。在这项研究中，建议使用净切削比能作为测量 316 不锈钢层间超声喷丸后机械性能的合适指标。能量消耗被映射到整个立方体构建体积的一半。结果表明，净切割比能的变化在远离表面的地方增加，并且与印刷和锻造相比，混合 AM 的变化更高。打印样品的净切割比能的平均横向和层状变化比对照高 81%，这表明非均质性程度显着更高。更多，结果表明，能耗是一个有效的过程特征，与显微硬度有很强的相关性。使用净切削比能测量基于残余应变的各向异性，并通过钻孔进行验证。所提出的技术有助于填补混合增材制造中的部分测量空白，并利用对 AM 零件加工的预先存在的需求，在一次铣削操作中实现表面光洁度和质量评估的目标。