Abstract

Abstract for Masters
Investigating how electropolishing influences the surface roughness of aluminum parts fabricated through additive manufacturing (3D printing), with a focus on optimizing process parameters and comparing electrolyte systems.

Nadia Eslami, Masters
Concordia University,2025
Producing complex metal components, particularly with aluminum-based alloys, has been significantly advanced by the growing adoption of 3D printing technologies. However, the surface finish of 3D-printed parts remains a key challenge, often requiring post-processing to meet the quality standards for functional applications. Electropolishing is a promising surface finishing technique that can enhance the smoothness and uniformity of metal parts by selectively dissolving microscopic surface asperities.
The present research investigates the effect of electropolishing on the surface roughness of 3D-printed aluminum-based alloys, specifically AlSi10Mg and a custom alloy referred to as CP1. The study focuses on evaluating and optimizing key process parameters—including electrolyte composition, applied voltage, polishing duration, and bath temperature—to determine their influence on surface quality. Two electrolytic systems are explored: a conventional acidic mixture (phosphoric and sulfuric acid) and a neutral organic system (ethylene glycol with sodium chloride).
Surface roughness changes are quantified using both portable contact profilometry and confocal laser scanning microscopy, enabling detailed analysis of topographical improvements. Comparative assessments between the two alloys and electrolyte systems offer insights into the electropolishing behavior of different microstructures and alloy chemistries.
The findings contribute to a deeper understanding of electropolishing as a viable finishing method for improving the surface condition of additively manufactured aluminum components and guiding process selection for industrial applications requiring high surface quality.