Currently, additively manufactured (AM) parts have a high initial surface roughness after the manufacturing process, which can be a limitation for application in highly stressed and cyclically loaded areas. In the present study, Ti-6Al-4V samples were manufactured by laser beam melting, annealed and hot isostatically pressed afterwards. They showed an initial surface roughness of R a = 17.9 μm depending on their build direction (45°). Subsequently, four different mechanical surface finishing processes were applied separately on plates and fatigue coupons in order to reduce the surface roughness: Milling, blasting, vibratory grinding and a micro machining process. The effectiveness of each treatment is evaluated with respect to the surface topography, as well as the fatigue properties based on axial fatigue tests performed in accordance to DIN EN 6072. The initial roughness could often be reduced to values R a 7 cycles).
