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Materials
Volume 18
Issue 23
10.3390/ma18235315
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Application of Laser and Cryogenic Surface Treatment for the Evolution of Surface Morphology in Additively Manufactured Ti-6Al-4V Alloy Samples

by
Dorota Laskowska
1,*,
Monika Szada-Borzyszkowska
1,*,
Błażej Bałasz
1,
Wiesław Szada-Borzyszkowski
2 and
Izabela Bukała
3
1
Faculty of Mechanical Engineering and Energy, Koszalin University of Technology, Śniadeckich 2, 75-620 Koszalin, Poland
2
Branch of the KUT in Szczecinek, Koszalin University of Technology, 78-400 Szczecinek, Poland
3
Emtech Iph Group, Krzywa 3, 59-100 Polkowice, Poland
*
Authors to whom correspondence should be addressed.
Materials 2025, 18(23), 5315; https://doi.org/10.3390/ma18235315
Submission received: 27 October 2025 / Revised: 18 November 2025 / Accepted: 24 November 2025 / Published: 25 November 2025
(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)
Versions Notes

Abstract

This study investigates the effects of laser and cryogenic (dry ice) surface treatments on enhancing surface characteristics of Ti-6Al-4V titanium alloy components produced using the Selective Laser Melting (SLM) technique. Components produced via additive manufacturing often exhibit increased surface irregularities and residual unmelted powder, which can deteriorate their mechanical strength and resistance to corrosion. In this study, SLM samples manufactured with two laser powers (176 W and 220 W) were subjected to laser cleaning and dry ice blasting under various process parameters. Surface topography and morphology analyses were performed. The obtained results showed that both methods improved surface uniformity and removed contaminants. Dry ice treatment effectively removed loose powder particles and impurities without causing structural changes—the best results were obtained at a pressure of 10 bar. Laser treatment, depending on the focal length, produced varying degrees of surface remelting—from gentle smoothing (500 mm) to intensive thermal effects and microcracks (250 mm). The research confirmed that cryogenic cleaning is an environmentally friendly and safe post-processing method, while laser cleaning enables deeper surface structure modification, requiring further optimization.
Keywords: additive manufacturing; laser powder bed fusion; Ti-based alloy; laser treatment; dry ice additive manufacturing; laser powder bed fusion; Ti-based alloy; laser treatment; dry ice

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MDPI and ACS Style

Laskowska, D.; Szada-Borzyszkowska, M.; Bałasz, B.; Szada-Borzyszkowski, W.; Bukała, I. Application of Laser and Cryogenic Surface Treatment for the Evolution of Surface Morphology in Additively Manufactured Ti-6Al-4V Alloy Samples. Materials 2025, 18, 5315. https://doi.org/10.3390/ma18235315

AMA Style

Laskowska D, Szada-Borzyszkowska M, Bałasz B, Szada-Borzyszkowski W, Bukała I. Application of Laser and Cryogenic Surface Treatment for the Evolution of Surface Morphology in Additively Manufactured Ti-6Al-4V Alloy Samples. Materials. 2025; 18(23):5315. https://doi.org/10.3390/ma18235315

Chicago/Turabian Style

Laskowska, Dorota, Monika Szada-Borzyszkowska, Błażej Bałasz, Wiesław Szada-Borzyszkowski, and Izabela Bukała. 2025. "Application of Laser and Cryogenic Surface Treatment for the Evolution of Surface Morphology in Additively Manufactured Ti-6Al-4V Alloy Samples" Materials 18, no. 23: 5315. https://doi.org/10.3390/ma18235315

APA Style

Laskowska, D., Szada-Borzyszkowska, M., Bałasz, B., Szada-Borzyszkowski, W., & Bukała, I. (2025). Application of Laser and Cryogenic Surface Treatment for the Evolution of Surface Morphology in Additively Manufactured Ti-6Al-4V Alloy Samples. Materials, 18(23), 5315. https://doi.org/10.3390/ma18235315

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