Selective laser melting (SLM) enables the production of metal complex shapes that are difficult or impossible to obtain with conventional production processes. However, the attainable surface quality is insufficient for most applications; thus, a secondary finishing is frequently required. Barrel finishing is an interesting candidate but is often applied without consistent criteria aimed at finding processing parameters. This work presents a methodology based on Bagnold number evaluation and bed behavior diagram, developed on experimental apparatus with different charges and process parameters. The experimentation on an industrial machine and the profilometric analysis allowed the identification of appropriate process parameters and charge media for finishing the investigated materials (Ti6Al4V and Inconel718). Two case studies, characterized by complex shapes, were considered, and consistent surface measures allowed understanding the capability of the technology.

Lightweight structures with an internal lattice infill and a closed shell have received a lot of attention in the last 20 years for satellites, due to their improved stiffness, buckling strength, multifunctional design, and energy absorption. The geometrical freedom typical of Additive Manufacturing allows lighter, stiffer, and more effective structures to be designed for aerospace applications. The Laser Powder Bed Fusion technology, in particular, enables the fabrication of metal parts with complex geometries, altering the way the mechanical components are designed and manufactured. This study proposed a method to re-design the original satellite structures consisting of walls and ribs with an enclosed lattice design. The proposed new structures must comply with restricted requirements in terms of mechanical properties, dimensional accuracy, and weight. The most challenging is the first frequency request which the original satellite design, based on traditional fabrication, does not satisfy. To overcome this problem a particular framework was developed for locally thickening the critical zones of the lattice. The use of the new design permitted complying with the dynamic behavior and to obtain a weight saving maintaining the mechanical properties. The Additive Manufacturing fabrication of this primary structure demonstrated the feasibility of this new technology to satisfy challenging requests in the aerospace field.

Metal additive manufacturing is a rapidly growing field based on the fabrication of complex parts with improved performance. The advantages of using this technology include the production of shapes that cannot be produced by traditional machining technologies, the possibility of using trabecular reinforcing structures, and the ability to make parts with topological optimization that allow for increased performance and decreased mass of the parts produced. Metal parts produced by selective laser melting technology exhibit high surface roughness, which limits their direct implementation. Corrosion protection of these surfaces is difficult, especially for galvanic processes. This paper analyzes the possibility of using sol–gel silica (silicon oxide) coatings to effectively protect various surfaces of aluminum alloys produced by selective laser melting technology. Silicon oxide sol–gel protective coatings have demonstrated excellent chemical stability and corrosion resistance, being able to be applied in very thin layers. These properties make them excellent candidates for protecting additive-manufactured metal parts, especially as-built surfaces with a high surface roughness. Nanostructured silica sol–gel protective coatings have demonstrated excellent corrosion resistance and have the potential to replace the highly toxic chromium-based galvanic treatments. Using nanostructured silica sol–gel coatings, aluminum parts can be seamlessly integrated into circular-economy cycles.