Surface finishing is challenging in the context of additively manufactured components with complex geometries. Magnetic abrasive finishing (MAF) is a promising surface finishing technology that can refine the surface quality of components with complex shapes produced by additive manufacturing. However, there is insufficient study regarding the impact of MAF on microstructure–property relationships for additively manufactured builds, which is critical for evaluating mechanical performance. In this work, we studied the effects of different combinations of MAF and heat treatment steps on the microstructure–property relationships of Inconel 718 superalloys made by laser powder bed fusion (LPBF). The application of MAF was found to significantly reduce the surface roughness and refine the grain size of aged alloys. Moreover, MAF was able to increase the alloy elongation, which could be further influenced by the sequence of MAF and different heat treatment steps. The highest elongation could be achieved when MAF was performed between homogenization and aging processes. This work indicates that an effective combination of surface finishing and heat treatment is critical for the improvement of alloy performance. Furthermore, it demonstrates a promising solution for improving the performance of LPBF Inconel 718 by integrating MAF and heat treatment, which provides new perspectives on the post-processing optimization of additively manufactured alloys.

The attainment of the desired strength of the Inconel 718 superalloy heavily relies on the isothermal aging process, which plays a critical role in achieving the anticipated hardening effect. Surprisingly, there remains a dearth of dedicated studies investigating the influence of homogenization on phase transformations during the isothermal aging process, leaving a gap in the knowledge required to guide the design of post-heat treatment strategies. Addressing this gap, our work investigates the impact of homogenization time on phase transformations during isothermal aging at 730 °C in Inconel 718 alloys produced via additive manufacturing (AM) and suction casting (SC) methods. Intriguingly, we observe contrasting behaviors in the particle size of γ″ and γ′ in aged samples, depending on the homogenization time and the alloy processing method. Specifically, in AM alloys, extended homogenization time leads to an increase in the particle size of γ″ and γ′, whereas the opposite trend is observed in SC alloys. Furthermore, despite undergoing the same heat treatment, the AM alloys exhibit smaller particle sizes but higher precipitate number densities compared to the SC alloys, resulting in superior hardness. Notably, pronounced grain refinement during aging is evident in 1 h homogenized SC samples under 1180 °C, warranting further investigations into the underlying mechanisms. This study elucidates the crucial role of homogenization in attaining the desired microstructure following subsequent aging processes. Moreover, it offers novel insights for developing post-heat treatment strategies for superalloys.