Machining Performance Measures of High Temperature Heat Resistant Super alloys: A Review

Abstract With the advanced material technology in the space and aviation enterprises, superalloys are identified as a major challenge in a high-temperature work environment. Heat resistant super alloys have a high temperature, strength, creep, and corrosion resistant material find its application in the industrial turbine, atomic, submarine aircraft sectors. In addition, the important properties are needed generally utilized in heat exchangers, atomic reactors, and turbine blades. Because of its high weight to strength proportion, its exploitation in the aerospace and aeronautical industry is widespread. For more than a decade, the significance for cost-effective and environment-friendly machining has gained popularity among numerous researchers for developing more advanced machining process. Minimization of tooling wear extends the life span consequently lessens the tool cost is the focal intention of any manufacturing system. During hard materials machining, the appropriate choice of cutting approach and cooling situations play an important aspect that influences the machining system. The current article presents on a comprehensive overview of various machining process (drilling, turning, and milling) during machining of super alloys particularly, Inconel 800, Incoloy 800, Inconel 706, Inconel 825, and Inconel 718 etc. The machining attributes exploration for Nickel-based superalloys grades has become a promising topic for research advance technology based thermal barrier insulating materials are used to progress service performance of parts. Moreover, comparisons are reviewed between various cutting systems like cryogenic, MQL and dry environments. In Sum, experimental and theoretical perceptions for surface quality, temperature, and wear of the tool exerting on the various types of cooling conditions and cutting inserts were summarized. This overview will definitely helpful for the practical perspective of manufacturing, academic researchers as well as cutting tool manufacturers.

[1]  Stanislaw Legutko,et al.  The influence of the cooling conditions on the cutting tool wear and the chip formation mechanism , 2016 .

[2]  Janez Kopac,et al.  Sustainable machining of high temperature Nickel alloy – Inconel 718: part 1 – predictive performance models , 2014 .

[3]  Danil Yu. Pimenov,et al.  Artificial Intelligence Monitoring of Hardening Methods and Cutting Conditions and Their Effects on Surface Roughness, Performance, and Finish Turning Costs of Solid-State Recycled Aluminum Alloy 6061 Сhips , 2018, Metals.

[4]  Ş. Karabulut,et al.  Dynamic Chip Breaker Design for Inconel 718 Using Positive Angle Tool Holder , 2008 .

[5]  M. A. Xavior,et al.  Tool Wear Assessment During Machining of Inconel 718 , 2017 .

[6]  E. Budak,et al.  Investigation of machinability in turning of difficult-to-cut materials using a new cryogenic cooling approach , 2018 .

[7]  S. Dominiak,et al.  Dry machining of Inconel 718, workpiece surface integrity , 2011 .

[8]  Pedro J. Arrazola,et al.  Surface Integrity Analysis when Machining Inconel 718 with Conventional and Cryogenic Cooling , 2016 .

[9]  Song Zhang,et al.  Tool life and cutting forces in end milling Inconel 718 under dry and minimum quantity cooling lubrication cutting conditions , 2012 .

[10]  Knut Sørby,et al.  A Review on Minimum Quantity Lubrication for Machining Processes , 2015 .

[11]  Ş. Karabulut,et al.  Performance analysis of new external chip breaker for efficient machining of Inconel 718 and optimization of the cutting parameters , 2018 .

[12]  L. Vijayaraghavan,et al.  A Study on the Parameters in High-Speed Turning of Superalloy Inconel 718 , 2009 .

[13]  Z. M. Wang,et al.  The machinability of nickel-based alloys: a review , 1999 .

[14]  Keith Ridgway,et al.  An analysis of the residual stresses generated in Inconel 718™ when turning , 2006 .

[15]  Che Hassan Che Haron,et al.  Tool wear and surface integrity of inconel 718 in dry and cryogenic coolant at high cutting speed , 2017 .

[16]  Munish Kumar Gupta,et al.  Surface roughness measurements in NFMQL assisted turning of titanium alloys: An optimization approach , 2017, Friction.

[17]  Gopala Rao Thellaputta,et al.  Machinability of Nickel Based Superalloys: A Review , 2017 .

[18]  M. Gupta,et al.  Machining comparison of aerospace materials considering minimum quantity cutting fluid: A clean and green approach , 2017 .

[20]  Rudolph F. Laubscher,et al.  Sustainable machining of titanium alloys: A critical review , 2017 .

[21]  E. Ezugwu.  Key improvements in the machining of difficult-to-cut aerospace superalloys , 2005 .

[22]  Chengdong Wang,et al.  Tool wear performance in face milling Inconel 182 using minimum quantity lubrication with different nozzle positions , 2014 .

[23]  Anurag,et al.  A Brief Review on Machining of Inconel 718 , 2018 .

[24]  María Henar Miguélez,et al.  Analysis of tool wear patterns in finishing turning of Inconel 718 , 2013 .

[25]  K. N. Pandey,et al.  Thermal Cyclic Resistance Behavior of Inconel 800 Super Alloy Substrate with Thermal Barrier Coatings by Plasma Spraying , 2015 .

[26]  Weiju Ren,et al.  A Review of Alloy 800H for Applications in the Gen IV Nuclear Energy Systems , 2010 .

[27]  Xiaoming Zhang,et al.  Comparison of Residual Stresses in Cryogenic and Dry Machining of Inconel 718 , 2016 .

[28]  A. Kermanpur,et al.  Microstructural characterization of dissimilar welds between alloy 800 and HP heat-resistant steel , 2008 .

[29]  A. Kara,et al.  Wear behavior of solid SiAlON milling tools during high speed milling of Inconel 718 , 2017 .

[30]  Catalin Iulian Pruncu,et al.  Machinability Investigations of Inconel-800 Super Alloy under Sustainable Cooling Conditions , 2018, Materials.

[31]  Eren Kaya,et al.  Effects of cutting parameters on machinability characteristics of Ni-based superalloys: a review , 2017 .

[32]  Mozammel Mia,et al.  Modeling and optimization of tool wear in MQL-assisted milling of Inconel 718 superalloy using evolutionary techniques , 2018, The International Journal of Advanced Manufacturing Technology.

[33]  XiaoQi Chen,et al.  An experimental study of tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts , 2006 .

[34]  Mohammadreza Shabgard,et al.  On the feasibility of a reduction in cutting fluid consumption via spray of biodegradable vegetable oil with compressed air in machining Inconel 706 , 2015 .

[35]  A Aramcharoen,et al.  An Experimental Investigation on Cryogenic Milling of Inconel 718 and its Sustainability Assessment , 2014 .

[36]  Simon Barrans,et al.  Optimisation of machining parameters during ball end milling of hardened steel with various surface inclinations , 2017 .

[37]  B. Davoodi,et al.  Cutting forces and surface roughness in wet machining of Inconel alloy 738 with coated carbide tool , 2016 .

[38]  J. S. Senthilkumaar,et al.  Investigations of surface roughness and flank wear behaviour in machining of Inconel 718 , 2012 .

[39]  J. Ghani,et al.  Surface integrity of Inconel 718 when finish turning with PVD coated carbide tool under MQL , 2011 .

[40]  Mozammel Mia,et al.  Effects of internal cooling by cryogenic on the machinability of hardened steel , 2017 .

[42]  S. Gangopadhyay,et al.  Investigation on Some Machinability Aspects of Inconel 825 During Dry Turning , 2015 .

[43]  Manu Dogra,et al.  Performance evaluation of coated carbide tool in machining of stainless steel (AISI 202) under minimum quantity lubrication (MQL) , 2015 .

[44]  D. Ulutan,et al.  Machining induced surface integrity in titanium and nickel alloys: A review , 2011 .