Surface finishing the additive manufactured IN625 fuel nozzles using

multi-jet hydrodynamic cavitation abrasive finishing

Arun Prasanth Nagalingam1, 2, Lee Jian-Yuan1, 2, S. H. Yeo1, 2(*)
1School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore
639798, Singapore.
2 Rolls-Royce@NTU Corporate Lab, N3.1-B2a-01, 50 Nanyang Avenue, Singapore 639798, Singapore
(*) E-mail: MSHYEO@ntu.edu.sg.

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 Section - 1
Additive Manufacturing the Internal Channels

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Fuel nozzle coupons final dimensions
Convergent injection nozzle Divergent spray nozzle

Coupon ID (mm) Coupon ID (mm)

Convergent (1) 10.01 Divergent (1) 10.00
Convergent (2) 10.00 Divergent (2) 9.99
Convergent (3) 10.01 Divergent (3) 9.98

Coupon ID (mm) Coupon ID (mm)

Convergent (1) 10.00 Divergent (1) 9.98
Convergent (2) 9.99 Divergent (2) 9.98
Convergent (3) 10.00 Divergent (3) 9.98

Coupon ID Height (mm) Coupon ID Height (mm)

Convergent (1) 50.009 Divergent (1) 50.022
Convergent (2) 50.066 Divergent (2) 50.034
Convergent (3) 50.019 Divergent (3) 50.026

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Fuel nozzle coupons final dimensions

STEP - 1 STEP - 2 STEP - 3

Fuel nozzles Support structures As-built nozzle

with additional material for on powder bed surrounded
machining and fixturing by support structures to prevent
build collapse

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 Section - 2
Process Parameter Selection

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 Cavitation loop Slurry loop

• Pump frequency was varied to increase the pumping pressures

• The pressure corresponding to each nozzle size and operating frequency is shown in the respective graphs
• The minimum cavitation inlet pressure (using 0.5 mm nozzle) and the maximum slurry inlet pressure (using 3.00 mm
nozzle) is selected for the case study
• However, any desired pressure can be selected if required
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Nozzle diameter

The ratio of nozzle diameter to the workpiece diameter was maintained ≤ 1. If the ratio exceeds the value of 1, there
workpiece inlet will be eroded

Nozzle Nozzle
Erosion zone
workpiece workpiece

Abrasive concentration

The use of abrasive concentration ≤ 1.0 % gives rise to synergistic effects in hydrodynamic finishing. The details of
synergistic effects are provided in our previous studies.

Fluid temperature

The fluid temperature was maintained at room temperature for this case study. However, cavitation and the associated
material removal is maximum at 50 °C.

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 Section - 3
As-built Surface Irregularities

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As-built surface irregularities on the internal surfaces
Partially melted Pores, crack
powders beneath staircase

Pore

Pore

Pores

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 Section - 4
Location Specific Surface Topography

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Areal surface topography

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Areal surface topography

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Areal surface topography

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 Divergent spray nozzle (as-built)
Areal surface topography

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 Divergent spray nozzle (HAF)
Areal surface topography

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 Divergent spray nozzle (HCAF)
Areal surface topography

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