Low-Cost Method for Internal Surface Roughness Reduction of Additively Manufactured All-Metal Waveguide Components

Jakub Sorocki; Ilona Piekarz; Michał Baranowski; Adam Lamęcki; Alberto Cattenone; Stefania Marconi; Gianluca Alaimo; Nicolo Delmonte; Lorenzo Silvestri; Bozzi Maurizio

doi:10.1109/tmtt.2024.3361976

Low-Cost Method for Internal Surface Roughness Reduction of Additively Manufactured All-Metal Waveguide Components

Abstract

In this study, a novel low-cost polishing method for internal surface roughness reduction of additively manufactured components, developed for waveguide (WG) circuits operating in the millimeter frequency range is proposed. WG components fabricated using powder bed fusion (PBF) generally feature roughness of ten to fifty microns, which influences the increase of roughness-related conductor power losses having a major effect on the electrical performance of additively manufactured allmetal WGs. To improve and decrease the surface roughness of circuits fabricated using PBF, glass microbeads as an abrasive medium are proposed to be used in combination with a rotary tumbler. This technique allows the abrasive medium to efficiently penetrate internal long channels and cavities, having cross section dimensions in the range of sub- to a few millimeters. An experimental study was carried out on an example of WG sections and bandpass filters fabricated using PBF through selective laser melting (SLM), operating within the 8.2 to 40 GHz range. Polishing impact on both mechanical and electrical properties was studied showing surface roughness reduction by 18% and sixth order filter’s insertion loss reduction at 23 GHz by 40% after 24 h of tumbling with 300–400 µm large glass microbeads.

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Authors (10)

Jakub Sorocki dr hab. inż.
- Akademia Górniczo-Hutnicza im. Stanisława Staszica w Krakowie Wydział Informatyki, Elektroniki i Telekomunikacji Instytut Elektroniki
Ilona Piekarz dr hab. inż.
- Akademia Górniczo-Hutnicza im. Stanisława Staszica w Krakowie Wydział Informatyki, Elektroniki i Telekomunikacji Instytut Elektroniki
Michał Baranowski
Adam Lamęcki dr hab. inż.
Alberto Cattenone
- Uniwersytet w Pawii
Stefania Marconi
- Uniwersytet w Pawii
Gianluca Alaimo
- Uniwersytet w Pawii
Nicolo Delmonte
- Uniwersytet w Pawii
Lorenzo Silvestri
- Uniwersytet w Pawii
Bozzi Maurizio prof.
- Uniwersytet w Pawii

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Category:

Articles

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artykuły w czasopismach

Published in:

IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES pages 1 - 11,
ISSN: 0018-9480

Language:

English

Publication year:

2024

Bibliographic description:

Sorocki J., Piekarz I., Baranowski M., Lamęcki A., Cattenone A., Marconi S., Alaimo G., Delmonte N., Silvestri L., Maurizio B.: Low-Cost Method for Internal Surface Roughness Reduction of Additively Manufactured All-Metal Waveguide Components// IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES -, (2024), s.1-11

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