Browsing by Author "Sekar, P."

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A study on the effect of process parameters and scan strategies on microstructure and mechanical properties of laser directed energy deposited IN718
(Elsevier Ltd, 2023) Thanumoorthy, R.S.; Sekar, P.; Bontha, S.; Balan, A.S.S.
The present study focuses on understanding the effect of scan strategy on the microstructure and mechanical properties of LDED fabricated IN718 built at optimized process conditions from single track analysis. Initially, single track studies were conducted by varying laser power, scan speed, and feed rate (3 levels) to optimize process parameters for bulk deposition. Based on the dilution, aspect ratio, track continuity and melt pool shape, best process parameter were chosen for depositing bulk structures. Bulk rectangular specimens were fabricated using the LDED process for different infill rotation (0°, 45°, 67°, and 90°) at optimized process conditions. Infill rotation did not show any significant change in the density of the samples. However, grain size measurement from EBSD and SEM micrographs revealed a substantial difference in grain size between samples without infill rotation (0°) and samples with infill rotation (45°, 67°, and 90°). XRD and EDS mapping revealed higher the formation of secondary laves phases with infill rotation as a result of higher cooling rate. Similarly, melt pool shape and arrangement showed significant variation with different infill angles. Samples with 0° and 90° infill rotation exhibited strong crystallographic texture along the build direction. There was a significant variation in the microhardness and tensile strength of the build with variation in infill rotation. This variation in mechanical properties were attributed to grain size, LAGB's fraction, secondary phases, and crystallographic texture. © 2023 Elsevier B.V.
A study on the influence of WEDM parameters on surface roughness, kerf width, and corrosion behavior of AZ31B Mg alloy
(Elsevier Ltd, 2022) Chaitanya, V.H.; Sekar, P.; Narendranath, S.; Balaji, V.
Wire electric discharge machining (WEDM) is a nontraditional machining process where the material is removed by the spark erosion technique. This technique is used to machine AZ31B, a biodegradable Magnesium alloy. In the present work impact of WEDM input parameters, namely pulse on time (Ton), pulse off time (Toff), servo voltage (SV), and wire feed (WF) on response characteristics is studied. The response characteristics considered are kerf width (KW), surface roughness (SR), and corrosion rate (CR). L9 orthogonal array by Taguchi's is employed as the design of experimentation. Taguchi's analysis implied that TON is the most influencing input parameter on the response characteristics. At a relatively lower TON setting (105 μs), comparatively lesser kerf width (335.894 μm), lower surface roughness (3.069 μm), and lower corrosion rate (0.95 mm/year) are exhibited by the machined specimens. From the main effects plots using signal-to-noise ratios, it is understood that the values of response characteristics increased with an increase in TON value. It is due to the increase in discharge at the more pulse on time duration. It is also understood that a surface with relatively better surface finish exhibited better corrosion resistance. With the help of regression equations, the relation between response characteristics and input parameters is built. © 2022 The Combustion Institute. Published by Elsevier Inc. All rights reserved.
Additive manufacturing of magnesium alloys: Characterization and post-processing
(KeAi Publishing Communications Ltd., 2024) Manjhi, S.K.; Sekar, P.; Bontha, S.; Balan, A.S.S.
Magnesium and its alloys remain perilous in the framework of light weighting and advanced devices structure such as rockets and satellites. However, the utilization of Magnesium (Mg) is increasing every year, revealing growing demands in manufacturing industries. Manufacturing of Mg components is challenging because of their HCP crystal structure and limited ductility. In this context, additive manufacturing (AM) provides the flexibility to manufacture complex shape components with excellent dimensional stability. It also provides a new possibility for utilizing novel component structures that increase the applications for Mg alloy. This review herein pursues to holistically explore the additive manufacturing of Mg alloy with a synopsis of processes used and microstructure, mechanical properties, corrosion behaviour and postprocessing of AMed Mg alloy. The challenges and future scope of AMed Mg alloys are critically explored. © 2023 The Authors
An Experimental Investigation on Microstructure, Mechanical Properties and Corrosion Performance of CMT-Wire Arc Additively Manufactured Al-4043 Alloy
(Springer, 2023) Manjhi, S.K.; Kumar, B.S.S.; Rodrigues, J.P.; Sekar, P.; Bontha, S.; Balan, A.S.S.
The wire arc additive manufacturing process (WAAM) has drawn incredible potential to manufacture non-ferrous alloys such as Aluminium and Magnesium. The deposition of Aluminium using a conventional WAAM process resulted in various defects such as porosity, cracks and tensile residual stress owing to high heat input. Therefore, to address these challenges, cold metal transfer wire arc additive manufacturing process (CMT-WAAM) is used to deposit 4043 Al alloy. The microstructure, mechanical properties and corrosion performance of Al 4043 are evaluated to ascertain the quality of deposited parts. The XRD peak intensity and microstructure shows that the main phases are α-Al and MgSi2 eutectics distributed along the grain boundaries of the Al matrix. The grain size of the bottom section is relatively smaller than the middle and top sections due to the high thermal gradient at the beginning of the deposition. Therefore, the hardness increases from the bottom to the top section of the thin wall. In addition, variations in the fraction of secondary phases are also responsible for the variation in hardness. The average UTS and % EL of travel direction (TD) are 177 ± 5 MPa and 20 ± 0.3%, which are relatively higher than the average UTS (164 ± 2 MPa) and % EL (17 ± 0.5%) of build direction (BD). However, the differences are only 10 ± 3 MPa and 2 ± 0.3% EL, exhibiting isotropic mechanical properties. The corrosion rates of the bottom, middle and top sections are 0.172, 0.116 and 0.102 mm/year, which are comparable, exhibiting uniform corrosion resistance of the deposited thin wall. © 2023, The Indian Institute of Metals - IIM.
Bio-corrosion impacts on mechanical integrity of ZM21 Mg for orthopaedic implant application processed by equal channel angular pressing
(Springer, 2021) Sekar, P.; Nyahale, M.B.; Naik, G.M.; Narendranath, N.; Prabhu, A.; Rekha, P.D.
The mechanical integrity of rolled ZM21 Mg was improved by equal channel angular pressing (ECAP) to function as a potential biodegradable bone screw implant. Electron backscattered diffraction (EBSD) revealed deformed grains of 45 µm observed in rolled ZM21 Mg. They were transformed to equiaxed fine grains of 5.4 µm after 4th pass ECAP. The yield strength of rolled and ECAPed ZM21 Mg alloys were comparable. In contrast, 4th pass ZM21 Mg exhibited relatively higher elongation when compared to rolled sample. The mechanical properties of rolled and ECAPed ZM21 Mg were dependant on both grain refinement and crystallographic texture. The rolled and 4th pass ECAPed tensile samples exhibited nonlinear deterioration of mechanical properties when tested after 7, 14, 21 and 28 days immersion in Hank’s solution. The evaluation signifies that regardless their processing condition, ZM21 Mg alloys are suitable for surgical areas that requires high mechanical strength. In addition, the 4th pass ECAP samples were viable to MG-63 cells proving themselves to be promising candidates for future in vivo studies. [Figure not available: see fulltext.] © 2021, The Author(s).
Effect of CMT-WAAM Process Parameters on Bead Geometry, Microstructure and Mechanical Properties of AZ31 Mg Alloy
(Springer, 2024) Manjhi, S.K.; Sekar, P.; Bontha, S.; Balan, A.A.S.
Fabrication of Mg alloys using the additive manufacturing process is quite challenging owing to high oxidation and volatile nature at high temperatures. The present study investigates the effect of wire feed speed (WFS) and travel speed (TS) on single tracks of AZ31 Mg alloy fabricated using the cold metal transfer wire arc additive Manufacturing (CMT-WAAM) process. The WFS and TS of CMT-WAAM are optimized to achieve better deposition quality. An increase in WFS increased the width, height, penetration depth, and heat-affected zone of single tracks. In addition, increasing TS decreased the deposited tracks' contact angle and height. The average grain size at the interface zone, center and top portion of single tracks are 35, 42, and 60 μm. The x-ray diffraction results show only the presence of primary phase α-Mg; interestingly, the β-Mg17Al12 and η-Al8Mn5 secondary phases are identified by SEM + EDS and TEM images. The microhardness increased from the substrate to the top section of single tracks due to the increased volume fraction of secondary-phase particles. Based on the best-chosen process parameters obtained from single-track deposition, a multilayer AZ31 Mg thin wall is deposited. The UTS, YS, and % EL of the deposited thin wall in travel direction (TD) are 222 MPa, 102 MPa, and 18%, while in build direction are 202 MPa, 110 MPa, and 14%, respectively. The tensile strength and elongation % of TD and BD samples exhibited comparable properties and were higher than cast AZ31 Mg alloy. © ASM International 2023.
Effect of equiaxed grains and secondary phase particles on mechanical properties and corrosion behaviour of CMT- based wire arc additive manufactured AZ31 Mg alloy
(Elsevier Ltd, 2023) Manjhi, S.K.; Sekar, P.; Bontha, S.; Balan, A.S.S.
Wire arc additive manufacturing (WAAM) has drawn tremendous attention for manufacturing large and complex components of lightweight material at a moderate cost due to its high deposition rate and energy efficiency. Generally, WAAM-Mg alloy comprises columnar and columnar dendrite grains due to high cooling rates and thermal gradients responsible for anisotropic mechanical properties. To overcome this challenge, in this work, CMT-WAAM, which generally uses comparatively low heat input (33% lower than conventional WAAM), was used to deposit AZ31 Mg thin wall. The metallurgical characterization of the deposited thin wall of the top (T), middle (M) and bottom (B) sections reveals equiaxed grains of average sizes ∼ 58, ∼ 63 and ∼ 38 µm, respectively. In addition, TEM results exhibit the formation of secondary phase particles, i.e., β-Mg17Al12 and ɳ-Al8Mn5. Further, the ultimate tensile strength (UTS) and % elongation (% EL) in the travel direction (UTS = 224 MPa, % EL= 23.47%) are superior to that obtained in the build direction (UTS = 217 MPa, % EL = 20.82%). The corrosion resistance of WAAMed AZ31 Mg alloy is higher than wrought (cold rolled) AZ31 Mg alloy in Hank's balanced salt solution (HBSS). The results of this study reveal the potential of CMT-WAAM to deposit different grades of Mg with desired microstructure, mechanical properties and corrosion resistance. © 2023 CIRP
Effect of Wire-EDM textures on corrosion performance of Bio-Degradable Mg alloy
(Elsevier B.V., 2024) Aswith Babu, I.; Kumar Manjhi, S.; Sekar, P.; Narendranath, S.; Balan, A.S.S.
Magnesium (Mg) is the most suitable material for biodegradable implant applications owing to its nontoxic behaviour and comparable Young's modulus to human bone. However, poor corrosion resistance limits its application. Therefore, surface texturing can be a more suitable and cost-effective technique to mitigate these issues. Hence, wire electric discharge machining (WEDM) is used to create various textures (wavy texture, microchannels, and micro-pillars) and investigate their influence on the corrosion resistance of Mg-Zn-Ca alloy. The results revealed that micropillar texture exhibited significantly lower surface roughness (Ra = 1.049 µm) and a higher contact angle indicative of hydrophobicity (130.3°), resulting in superior corrosion resistance (corrosion rate: 0.816 mm/year) compared to other textures and standard WEDM surfaces. These findings suggested that textured surfaces generated through WEDM hold the potential for enhancing the corrosion resistance of biodegradable Mg implants. © 2024 Elsevier B.V.
Effect of Zinc and Bio-Glass Addition on Mechanical Properties and Corrosion Behavior of Magnesium-Based Composites for Orthopedic Application: A Preliminary Study
(Springer, 2022) Moudgalya, K.V.S.; Sekar, P.; Hebbar, H.S.; Rahman, M.R.
Magnesium is extensively researched as a biodegradable implant material. However, achieving a combination of biomechanical properties viz., controlled degradation, bio-transformability and osteoconductivity is highly challenging. Indeed, bio-composites developed by reinforcing bio-ceramics with metals are gaining research interest. In this current work, the suitability of a bio-composite developed by reinforcing 5, 10 and 15% of bioglass (BG) in Mg and Mg-3 wt.% Zn metal matrix is investigated. The bio-composites containing Mg, Mg-BG and Mg-Zn-BG are processed by vacuum sintering and tested for important mechanical and corrosion properties. Particle size analysis revealed that magnesium exhibited a larger mean particle size while zinc evinced the lowest average particle size. The density-porosity analysis showed that porosity was found to increase linearly with the addition of BG. In contrast, the compressive strength of Mg-BG and Mg-Zn-BG composites increased up to 10 wt.% BG and decreased drastically for 15 wt.% BG reinforcement. The addition of Zn and BG significantly enhanced the Vickers hardness, showing an increasing trend with the increase in BG reinforcement content. Immersion corrosion study in phosphate buffered saline revealed that 10 wt.% BG reinforced composite exhibited the least corrosion rate. Thus, composites developed by reinforcing BG in Mg-3Zn metal matrix showed enhanced mechanical and corrosion properties in the physiological environment. The possible corrosion mechanism of Mg, Mg-Zn and Mg-Zn-BG composites is also proposed and compared. © 2022, ASM International.
Enhanced disinfection of E. faecalis and levofloxacin antibiotic degradation using tridoped B-Ce-Ag TiO2 photocatalysts synthesized by ecofriendly citrate EDTA complexing method
(Springer Science and Business Media Deutschland GmbH, 2022) Sekar, P.; Sadanand Joshi, D.; Manjunatha, M.; Mahalingam, H.
Since its use for photochemical water splitting reported first in 1972, TiO2 is one of the most extensively studied photocatalysts for a diverse range of applications. Monodoping or codoping of the catalyst is a proven strategy to enhance the functionality of TiO2 under solar or visible light. However, the use of three or more dopants in the development of more efficient and visible light active photocatalysts has not been investigated widely, especially for microbial disinfection. Boron/cerium/silver tridoped TiO2 photocatalysts with curated amounts of the dopants (B = 1, 2 at.%, Ce = 0.1 at.%, Ag = 0.06 at.%), synthesized by the ecofriendly EDTA-citrate method, were evaluated for the disinfection of water using Enterococcus faecalis under UV-A irradiation and degradation of levofloxacin antibiotic under solar light. The catalyst characterization revealed that the spherical nanoparticles had a crystallite size of ~ 13 nm and bandgap energy values of 2.8–2.9 eV. 2B-0.1Ce-0.06Ag-TiO2 is the best catalyst for microbial disinfection with a log reduction and kinetic rate constant ~ 30 and ~ 4.5 times higher than those values determined for the other codoped or monodoped catalysts, confirming an enhanced performance. Regarding levofloxacin degradation, the best performing catalyst is 1B-0.1Ce-0.06Ag-TiO2 with degradation of 99% and 83% COD reduction in 100 min. The tridoped photocatalysts are very effective in the inactivation of Enterococcus faecalis, thus solving the problem of antimicrobial resistance in waters containing antibiotic residues. Graphical abstract: [Figure not available: see fulltext.] © 2022, The Author(s), under exclusive licence to Springer-Verlag GmbH Germany, part of Springer Nature.
Enhancement of resistance to galvanic corrosion of ZE41 Mg alloy by equal channel angular pressing
(2019) Sekar, P.; Sanna, N.; Desai, V.
The galvanic corrosion behavior of as-received and ECAPed ZE41 Mg alloy coupled with Al7075 alloy is investigated using zero resistance ammeter in three different corrosive environments, 0, 0.1, and 1 M NaCl, to mimic the conditions experienced in engineering applications. The mechanism of galvanic corrosion for the ZE41 Mg Al7075 aluminum alloy is explained. It is observed that a robust surface film containing a composite layer of oxide/hydroxide of magnesium and aluminum is established in deionized water (0 M). However, only a single layer of magnesium oxide/hydroxide is detected in chloride-containing environments. Equal channel angular pressing (ECAP) improved the resistance to galvanic corrosion by 58% and 54% when compared with the as-cast counterparts in 0 and 1 M NaCl solution, respectively. In contrast, galvanic corrosion resistance decreased by 26% in 0.1 M NaCl after ECAP while the as-received samples evinced pits unfavorable to be used in engineering applications. ECAP is a promising method to combat galvanic corrosion encountered by ZE41 magnesium alloy used in automobiles and components of military vehicles. 2019 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
Enhancement of resistance to galvanic corrosion of ZE41 Mg alloy by equal channel angular pressing
(Wiley-VCH Verlag info@wiley-vch.de, 2020) Sekar, P.; Sanna, N.; Desai, V.
The galvanic corrosion behavior of as-received and ECAPed ZE41 Mg alloy coupled with Al7075 alloy is investigated using zero resistance ammeter in three different corrosive environments, 0, 0.1, and 1 M NaCl, to mimic the conditions experienced in engineering applications. The mechanism of galvanic corrosion for the ZE41 Mg–Al7075 aluminum alloy is explained. It is observed that a robust surface film containing a composite layer of oxide/hydroxide of magnesium and aluminum is established in deionized water (0 M). However, only a single layer of magnesium oxide/hydroxide is detected in chloride-containing environments. Equal channel angular pressing (ECAP) improved the resistance to galvanic corrosion by 58% and 54% when compared with the as-cast counterparts in 0 and 1 M NaCl solution, respectively. In contrast, galvanic corrosion resistance decreased by 26% in 0.1 M NaCl after ECAP while the as-received samples evinced pits unfavorable to be used in engineering applications. ECAP is a promising method to combat galvanic corrosion encountered by ZE41 magnesium alloy used in automobiles and components of military vehicles. © 2019 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
Grinding parameters prediction under different cooling environments using machine learning techniques
(Taylor and Francis Ltd., 2023) Prashanth, G.S.; Sekar, P.; Bontha, S.; Balan, A.S.S.
Selection of optimum process parameters is vital for performing a sound grinding operation on Inconel 751 alloy. This paper co-relates the relationship between the most influential input parameters like cutting velocity, depth of cut, feed rate, and environmental conditions to the output parameters, namely, tangential grinding forces, normal grinding forces, temperature, and surface roughness. Three types of machine-learning (ML) algorithms such as support vector machine (SVM), Gaussian process regression (GPR), and boosted tree ensemble techniques are employed to develop a ML model for predicting the output variables during grinding operation of Inconel 751. In order to develop a better ML model, K-fold technique is employed on a total of 81 datasets which are extracted from experimental studies. ML models developed from different algorithms are compared based on performance metrics like R2 score and root-mean-square error (RMSE). GPR algorithm exhibits best results with relatively better R2 score and RMSE value in predicting grinding forces and temperature at wheel work interface. From analyzing the ML models, it is found that cooling environments determined the output grinding parameters to a greater extent when compared with the input grinding parameters. © 2022 Taylor & Francis.
Hybrid additive manufacturing of ER70S6 steel and Inconel 625: A study on microstructure and mechanical properties
(Elsevier Ltd, 2023) Rodrigues, J.P.; Thanumoorthy, R.S.; Manjhi, S.K.; Sekar, P.; Arumuga Perumal, D.A.; Bontha, S.; Balan, A.S.S.
Hybrid Additive Manufacturing (HAM) is currently being explored because of its potential to achieve trade-off between build capacity and feature resolution. The present study aims at fabricating ER70S6-Inconel 625 (IN625) bimetallic clad using hybrid Wire Arc Additive Manufacturing (WAAM) and Laser Directed Energy Deposition (LDED) processes. Microstructure evaluation was performed at the cross section of bimetallic clad for distinct materials as well as the interface. WAAM built ER70S6 revealed equiaxed ferritic grains, whereas laser deposited IN625 region showed columnar dendrites with under developed secondary arms. However, the first layer of IN625 exhibited columnar dendrite with secondary arms due to the influence of diffused Fe from the base ER70S6 steel under the action of concentrated laser heat source, which was revealed by energy dispersive spectroscopy (EDS) maps. The measured microhardness across the cross section of the deposit showed values corresponding to inherent material system. The interface did not reveal presence of any intermetallic phases which was confirmed by hardness results and X-Ray diffraction. Shear test revealed superior bond strength between the two materials, maintaining average strength of 452 MPa. The fractography images exhibited fine dimples along with cleavages indicating mixed fracture characteristics. This additive manufacturing method explores a new dimension in multi-material fabrication which, when customized for different materials, serve critical areas in the aerospace and defence sector. © 2023 Elsevier Ltd
Investigating the role of WEDM surface texturing in the degradation and biocompatibility of Mg–Zn–Ca alloy
(KeAi Publishing Communications Ltd., 2025) Aswith Babu, I.; Sekar, P.; Prabhu, A.; Narendranath, S.; Balan, A.S.S.
Magnesium (Mg) alloy-based biodegradable implants are gaining popularity for their low density, high strength, and biocompatibility. The corrosion and wear performance of Mg is poor in physiological environments, leading to premature failure. Surface modification, particularly through surface texturing, reduces the effective contact area of Mg–Zn–Ca alloy with corrosive media and tribological partners, potentially optimizing its degradation kinetics and cytocompatibility. Wire Electric Discharge Machining (WEDM) offers a stable oxide layer on the surface, unlike laser surface texturing, which may thermally damage the Mg alloy. In this study, three types of textures, mainly Wavy Texture (WT), microchannels (MC), and micropillars (MP), were created using WEDM on the Mg–Zn–Ca samples, and their corrosion, wear, cytotoxicity, and cell adhesion performance were evaluated. Texturing on the surface of the samples enhanced the corrosion performance, from 3.14 mm/year for the untextured sample to 0.98 mm/year for the micropillar textured sample, representing a 68.8 % reduction. This improvement after texturing is attributed to the superior surface finish (1.049 ?m) and increased hydrophobicity (130.3°), equating to a 50.8 % improvement. The coefficient of friction (COF) value decreased from 0.364 for an untextured sample to 0.208 for microchannels, a 42.9 % reduction, due to the entrapment of debris in the textures and effective heat transfer. The samples' cell adhesion and cell viability have been improved after texturing. The combination of cytocompatibility, appropriate mechanical properties, and a reduced bio-corrosion rate highlights the potential of this surface texturing method, utilizing WEDM, as a promising approach to enhance biodegradable implant materials. © 2025 The Authors. Publishing services by Elsevier B.V. on behalf of KeAi Communications Co. Ltdé This is an open access article under the CC BY license. http://creativecommons.org/licenses/by/4.0/
On the microstructure, texture and electrochemical properties of severely deformed and artificially aged lightweight AA2050 Al-Cu-Li alloy
(Institute of Physics, 2024) Jagadeesh, C.; Shivananda Nayaka, H.; Sekar, P.; Ramesh, S.; Anne, G.
Lightweight 3rd generation Al-Cu-Li alloy AA2050 was severely deformed via Multi Axial Forging (MAF) at 170 °C followed by artificial aging at 150 °C. Effect of MAF and post MAF aging on microstructure and precipitation was investigated using transmission electron microscopy (TEM). Formation of deformation bands and large dislocation cells were evident on MAF processed samples. Post MAF peak aging resulted in the distribution of fine T1 precipitates in grain interiors with reduction in grain boundary precipitation. Bulk texture studies reveal the formation of strong Goss and S texture components upon MAF processing. Further, low temperature artificial aging doesn’t exhibit significant changes in texture characteristics, either in terms of texture intensities or texture components. Polarization studies showed that peak aged samples exhibited better corrosion resistance compared to un-aged samples. Overall, 12 pass MAF processed and peak aged samples showed higher corrosion resistance. Further, corrosion surface morphologies examination revealed the change in corrosion mechanisms with thermomechanical treatments. Improved corrosion resistance after MAF and peak aging widens the requirements in aerospace and aircraft applications for such engineering alloys. © 2024 The Author(s). Published by IOP Publishing Ltd.
Recent progress in in vivo studies and clinical applications of magnesium based biodegradable implants – A review
(National Engg. Reaserch Center for Magnesium Alloys, 2021) Sekar, P.; Narendranath, N.; Desai, V.
Biodegradable magnesium has regained great attention due to its ability to temporarily offer mechanical strength and degrade completely once the injured pathological tissue is healed. A few clinical applications of Mg-based implants were reported in the last century. However, the knowledge and experience is being gained continuously by studying the host response and degradation behavior of Mg implant in animal models and clinical trials. This led to the development of commercial products emerging from Europe and Asia very recently. The potential of Mg implants in repairing fractures at upper and lower limb of large, small animal models and humans is compared and discussed in detail. In addition the possible future Mg implants that might treat problems concerning to urology and gynecology are reviewed. © 2020
Surface Characteristics of Low Plasticity Burnished Laser Directed Energy Deposition Alloy IN718
(Springer, 2024) Mohanraj; Thanumoorthy, R.S.; Sekar, P.; Muthuchamy, A.; Bontha, S.; Balan, A.S.S.
The research work focuses on a novel post-processing sequence to improve the surface integrity and residual stress characteristics of as-printed Inconel718 (IN718) samples. The as-printed IN718 samples are subjected to solution treatment at 1050 °C, two-step precipitation hardening (@ 720 °C for 8 h and @ 620 °C for 8 h), and low plasticity burnishing. Two different sequences were attempted. Sequence-1 involves solutionizing ? low plasticity burnishing followed by precipitation hardening, and sequence-2 includes solutionizing ? precipitation hardening followed by low plasticity burnishing. The experimental observations and detailed investigations revealed that the samples processed via sequence 2 exhibited a better surface finish. The microhardness of the samples of sequence 2 is 10% higher than their counterparts in sequence 1. The maximum residual stress of ?1375.33 MPa is obtained in sequence 1 as compared to the residual stress of ?1100.67 MPa in sequence 2. The influence of the processing sequences on the surface properties has been discussed in detail using the XRD and microstructural characterization supported with EBSD analysis. Graphic Abstract: (Figure presented.) © The Indian Institute of Metals - IIM 2024.