4.5 Review

A Comprehensive Review on the Conventional and Non-Conventional Machining and Tool-Wear Mechanisms of INCONEL®

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Article Materials Science, Multidisciplinary

Creep anisotropy behavior, deformation mechanism, and its efficient suppression method in Inconel 625 superalloy

Xudong Liu et al.

Summary: This study systematically investigated the mechanical properties and creep behavior of Inconel 625 alloy sheets with weak local textures, revealing significant anisotropy in creep life. The study found that the deformation mechanisms and strain compatibility differences were the main factors determining creep anisotropy. Furthermore, pre-stress aging treatment was proposed as an effective method to suppress creep anisotropy, reducing the discrepancy rate of creep life by nearly 50%.

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Article Nanoscience & Nanotechnology

Effect of microstructure on tensile properties of quenched and partitioned martensitic stainless steels

A. Sierra-Soraluce et al.

Summary: This article investigates the effect of chemistry and heat treatment parameters on the microstructure and properties of Q&P treated martensitic stainless steels. It is demonstrated that these steels show a good combination of enhanced strength and sufficient tensile ductility, with the ability of the martensitic matrix to accumulate plastic deformation playing an important role. The relationship between the Q&P process, microstructure, and properties is discussed.

MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING (2023)

Article Engineering, Mechanical

Fretting corrosion behavior of WC-10Co-4Cr coating on Inconel 690 alloy by HVOF thermal spraying

Meigui Yin et al.

Summary: WC-10Co-4Cr coating was deposited on the outside surface of Inconel 690 alloy tube using high-velocity oxygen fuel (HVOF) process. The coating-treated alloy tube exhibited better electrochemical corrosion response and wear behavior, especially in terms of fretting wear resistance.

TRIBOLOGY INTERNATIONAL (2023)

Article Engineering, Manufacturing

Machining performance comparison of Inconel 625 superalloy under sustainable machining environments

P. R. Rakesh et al.

Summary: The performance of machining Inconel 625 under different sustainable cooling methods was investigated in this study. Dry, minimum quantity lubrication (MQL), nanoMQL, and cryogenic cooling were chosen as sustainable cooling techniques. The effects of cutting speed, feed, and depth of cut on machinability were analyzed under different cooling conditions. Cryogenic cooling showed the best performance due to its high heat dissipation rate. Tool wear mechanisms and chip formation were also studied.

JOURNAL OF MANUFACTURING PROCESSES (2023)

Article Engineering, Mechanical

Microstructure, mechanical properties and machinability of 316L stainless steel fabricated by direct energy deposition

Hongjian Ding et al.

Summary: Additive/subtractive hybrid manufacturing (ASHM) technology combines the efficiency and material utilization of additive manufacturing (AM) with the dimensional accuracy and surface quality of subtractive manufacturing (SM) through direct energy deposition technology. This study utilized AM to rapidly generate the basic shape of stainless steel components and SM milling to achieve machined surface in order to investigate the forming mechanism and its effect on machinability. The rapid cooling rate in the direct energy deposition process led to grain refinement and precipitation of ferrite, resulting in improved hardness and tensile strength. There was no clear linear relationship between work hardening and cutting speed or feed per tooth due to the combination of shear strain strengthening effect and thermal softening effect. The fine grains and more molten pool boundaries obtained through AM led to larger work hardening depth during SM process. Finally, a variety of stainless steel components showed good surface quality and dimensional accuracy through ASHM process.

INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES (2023)

Article Engineering, Manufacturing

Influence of MoS2 and graphite-reinforced nanofluid-MQL on surface roughness, tool wear, cutting temperature and microhardness in machining of Inconel 625

Mayur A. Makhesana et al.

Summary: The machinability of nickel-based alloys is influenced by friction and heat. Metalworking fluids are a concern for health and the environment, so minimum quantity lubrication (MQL) is preferred. MQL using vegetable oil blended with nanoparticles improves machining performance. In this study, the machinability of Inconel 625 is assessed using graphite and molybdenum disulfide nanoparticles in sunflower oil. The nanofluids' properties, as well as the performance of dry, MQL, and nanofluid-MQL environments, are evaluated.

CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY (2023)

Article Computer Science, Software Engineering

Efficient 5-axis CNC trochoidal flank milling of 3D cavities using custom-shaped cutting tools

Pengbo Bo et al.

Summary: A novel method for trochoidal flank milling of 3D cavities bounded by free-form surfaces is introduced, which incorporates the shape of the tool into the optimization cycle and ensures high precision quality. It also supports multi-layer approach and maximizes the material removal rate while meeting machining tolerances.

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Article Engineering, Mechanical

Sulfuration corrosion failure analysis of Inconel 600 alloy heater sleeve in high-temperature flue gas

Chen Wei et al.

Summary: The sulfuration corrosion behavior of Inconel 600 alloy in high-temperature flue gas was studied. The alloy is susceptible to be corroded in high-temperature sulfur-containing atmosphere. The corrosion mechanism involves sulfur penetration and weakening of intergranular bonding strength, as well as the continuous generation and melting of low melting point sulfide.

ENGINEERING FAILURE ANALYSIS (2022)

Review Engineering, Manufacturing

Systematic review on tool breakage monitoring techniques in machining operations

Xuebing Li et al.

Summary: Tool condition monitoring is crucial in machining operations to maximize tool life and reduce the risks of tool breakage. Existing literature focuses on tool wear monitoring, but a comprehensive review of tool breakage monitoring techniques is lacking. This paper presents the first systematic review on tool breakage monitoring and provides guidance to avoid catastrophic tool failures during cutting processes.

INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE (2022)

Review Engineering, Chemical

Tool Wear in Nickel-Based Superalloy Machining: An Overview

Rui Wang et al.

Summary: Nickel-based superalloys are widely used in aerospace, petrochemical, and marine fields due to their excellent oxidation resistance, corrosion resistance, stability, and reliability at various temperatures. However, during the cutting process, the interaction between the tool and the workpiece generates a large amount of cutting heat. The low thermal conductivity of the workpiece causes the cutting heat to accumulate at the contact point, resulting in severe tool wear, reduced tool life, and increased production cost. This paper discusses the tool wear mechanisms in the machining process of nickel-based superalloys and summarizes the research status of failure mechanisms and tool wear optimization. It highlights the importance of controlling heat and improving the tool environment to prolong the service life of tools. The development prospects of tool wear prevention measures in the field of nickel-based alloy machining are also described.

PROCESSES (2022)

Article Chemistry, Physical

A Novel Flushing Mechanism to Minimize Roughness and Dimensional Errors during Wire Electric Discharge Machining of Complex Profiles on Inconel 718

Muhammad Umar Farooq et al.

Summary: This study investigates the influence of flushing attributes on wire electric discharge machining in the aeronautical industry. The optimized flushing mechanism was found to significantly improve dimensional precision and surface quality of the machined components, while reducing geometrical errors.

MATERIALS (2022)

Review Chemistry, Physical

The Joining of Copper to Stainless Steel by Solid-State Welding Processes: A Review

Gaurang R. Joshi et al.

Summary: This article reviews the joining mechanism of copper to stainless steel, emphasizing the possibility of achieving defect-free strong joints under different solid-state processing conditions. It also highlights the gaps and challenges in current research.

MATERIALS (2022)

Article Engineering, Manufacturing

Novel use of ultrasonic-assisted turning in conjunction with cryogenic and lubrication techniques to analyze the machinability of Inconel 718

Jay Airao et al.

Summary: A novel study proposes combining ultrasonic vibration with lubrication and cooling to enhance the machinability of Inconel 718, significantly reducing wear and improving surface quality. Experimental results show that under LCO2 conditions, both conventional turning and UAT reduce tool wear and power consumption compared to dry, wet, and MQL strategies.

JOURNAL OF MANUFACTURING PROCESSES (2022)

Article Materials Science, Multidisciplinary

Evaluation of milling parameters on the surface integrity of welded inconel 625

Monica C. R. Guimaraes et al.

Summary: Nickel-based alloys are widely used in aerospace components and the oil and gas industry. However, their machining is challenging due to their characteristics. This study evaluates the influence of tool geometry, feed rate, and cutting speed on the surface integrity of Inconel 625 cladding milling process. The results show that cutting speed has the greatest impact on specific cutting pressure, and both cutting speed and feed rate affect the thickness of the deformed layer. The surface and subsurface alterations caused by mechanical-thermal loadings have beneficial effects on corrosion resistance and compressive residual stress.

JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T (2022)

Article Materials Science, Multidisciplinary

A Tool Life Prediction Model Based on Taylor's Equation for High-Speed Ultrasonic Vibration Cutting Ti and Ni Alloys

Xiangyu Zhang et al.

Summary: This research proposes a high-speed ultrasonic vibration cutting method for the precision machining of titanium and nickel alloys. Experimental results show that the tool life can be significantly enhanced through effective cooling and ultrasonic vibration. The established tool life prediction model can be used to optimize cutting parameters and monitor the machining process.

COATINGS (2022)

Article Materials Science, Multidisciplinary

Optimization of Wire EDM Process Parameters on Cutting Inconel 718 Alloy with Zinc-Diffused Coating Brass Wire Electrode Using Taguchi-DEAR Technique

Lijun Liu et al.

Summary: The Inconel 718 alloy is widely used in the aerospace sector due to its superior mechanical properties and weldability. Wire electrical discharge machining is used to machine complex-shaped, high-strength materials. This research aims to enhance the machining process by using a zinc-diffused coating brass wire electrode and the Taguchi-DEAR methodology. The optimal arrangement of input factors was found, with the pulse-off time being the most significant factor in determining the quality measures.

COATINGS (2022)

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Parametric optimization of CNC-drilling of Inconel 718 with cryogenically treated drill-bit using Taguchi-Whale optimization algorithm

Aditya Kumar Sahoo et al.

Summary: This study investigates the effects of using cryogenic treated drill bit on the drilling operation of Inconel 718 superalloy. The study analyzes thrust force, torque, and surface roughness, and optimizes the process parameters using the Whale optimization algorithm. The results show that feed rate, spindle speed, and tool condition are the most significant factors affecting thrust force, torque, and surface roughness.

MATERIALS TODAY-PROCEEDINGS (2022)

Proceedings Paper Materials Science, Multidisciplinary

An overview of the machinability of alloy steel

Naresh Kumar Wagri et al.

Summary: Machinability is crucial for material machining and depends on various factors such as tool life, surface roughness, power consumption, and more. The influence of heat treatment on the machinability of alloy steel is discussed in this article, providing valuable insights for students and researchers in the field of machining.

MATERIALS TODAY-PROCEEDINGS (2022)

Proceedings Paper Materials Science, Multidisciplinary

Analysis of microhardness and degree of work hardening (DWH) while turning Inconel 718 with high pressure coolant environment

Sunil J. Raykar et al.

Summary: This study investigates the characteristics of Turning Inconel 718 with High Pressure Coolant Environment by analyzing the microhardness and degree of work hardening. The results show that there is a sudden change in microhardness at a depth of about 270-300 μm below the machined surface, and the microhardness in the machined zone gradually approaches the bulk microhardness.

MATERIALS TODAY-PROCEEDINGS (2022)

Article Engineering, Manufacturing

Experimental studies on cryogenic CO2 face milling of Inconel 625 superalloy

R. Anburaj et al.

Summary: This study conducted face milling operation on Inconel 625 superalloy using Design of Experiments (DOE) with different coolant environmental conditions. The results showed that the optimization in cryogenic CO2 coolant environment was the most favorable.

MATERIALS AND MANUFACTURING PROCESSES (2021)

Article Multidisciplinary Sciences

Effect of homogenization and solution treatments time on the elevated-temperature mechanical behavior of Inconel 718 fabricated by laser powder bed fusion

Eslam M. Fayed et al.

Summary: The present study investigated the impact of homogenization and solution treatment times on the mechanical properties and fracture mechanisms of LPBF-manufactured IN718 superalloy at elevated temperatures. It was found that different homogenization and solution treatment times could significantly affect the strength and ductility of the IN718 alloy.

SCIENTIFIC REPORTS (2021)

Review Engineering, Industrial

Future research directions in the machining of Inconel 718

Andrea De Bartolomeis et al.

Summary: Inconel 718 is a popular nickel-based superalloy extensively used in aerospace, automotive, and energy industries. However, machining of Inconel 718 remains challenging due to its short tool life and low productivity. Recent advances in cutting tool materials, coatings, geometries, and surface texturing for machining Inconel 718 have been reviewed, with a focus on the thermal conductivity of cutting tool materials. Process control based on sensor data for monitoring machining and detecting anomalies has been identified as crucial for machining safety critical components.

JOURNAL OF MATERIALS PROCESSING TECHNOLOGY (2021)

Review Automation & Control Systems

Residual stresses and heat treatments of Inconel 718 parts manufactured via metal laser beam powder bed fusion: an overview

Oscar Teixeira et al.

Summary: Additive manufacturing is a unique manufacturing process that can produce complex parts using metal laser beam powder bed fusion technology. Inconel 718, a commonly used superalloy, exhibits good mechanical properties at high temperatures. Different heat treatments can improve mechanical properties and reduce residual stresses and impurities in the manufactured components.

INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY (2021)

Article Green & Sustainable Science & Technology

Environment and economic burden of sustainable cooling/lubrication methods in machining of Inconel-800

Munish Kumar Gupta et al.

Summary: The research demonstrates that under sustainable machining conditions, the use of N-2 cooling can significantly reduce total machining cost, energy consumption, carbon emissions, and tool wear, while improving surface quality, which is beneficial for resource conservation and environmental protection.

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Characterization of precipitation in gradient Inconel 718 superalloy

Jie Ding et al.

Summary: IN718 superalloy's mechanical properties are largely determined by precipitates, with the precipitation of high-density hexagonal eta phase observed in nanograined IN718 alloy after heat treatment. Compressive stress from severe plastic deformation may inhibit the formation of certain phases while accelerating the precipitation of others, affecting the overall mechanical behavior of the alloy.

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Review Materials Science, Multidisciplinary

Characteristics and Wear Mechanisms of TiAlN-Based Coatings for Machining Applications: A Comprehensive Review

Vitor F. C. Sousa et al.

Summary: The machining process is still relevant in today's industry, with the development of tool coatings improving productivity and tool life. Advanced coatings like TiAlN doped with Ru, Mo and Ta show potential for enhanced mechanical properties and wear behavior. Research is focusing on nanolayered and nanocomposite TiAlN coatings for improved properties in machining applications.

METALS (2021)

Article Engineering, Manufacturing

Effects of hybrid nanofluids on machining performance in MQL-milling of Inconel X-750 superalloy

Senol Sirin et al.

Summary: The study investigated the machining performance of Inconel X-750 superalloy using nanoparticles with different shapes and properties. It was found that the hybrid nanofluid hBN/Grpt outperformed other hybrid conditions, showing significant improvement in tool life.

JOURNAL OF MANUFACTURING PROCESSES (2021)

Article Engineering, Industrial

Interface strength and mechanical properties of Inconel 718 processed sequentially by casting, milling, and direct metal deposition

F. Soffel et al.

Summary: The combination of casting, milling, and direct metal deposition in the hybrid manufacturing process can overcome limitations in conventional process chains, increasing material efficiency and design flexibility.

JOURNAL OF MATERIALS PROCESSING TECHNOLOGY (2021)

Review Engineering, Manufacturing

Machinability of Inconel 718: A critical review on the impact of cutting temperatures

Kore Mahesh et al.

Summary: The demand for high temperature resistant superalloys like Inconel 718 is rising rapidly due to their superior properties, but machining can lead to high temperatures and tool wear. As a result, industries are moving towards environmentally friendly machining processes, such as dry machining, to reduce cutting temperatures.

MATERIALS AND MANUFACTURING PROCESSES (2021)

Article Automation & Control Systems

Electrode wear pattern during EDM milling of Inconel 718

Mikhail Kliuev et al.

Summary: Electrical discharge machining (EDM) milling is a relatively new method used for difficult-to-cut materials, allowing for machining of complex geometries using standard shape electrodes. Optimizing machining strategy can enhance shape precision and reduce milling time.

INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY (2021)

Article Engineering, Mechanical

An experimental study on the fretting wear behavior of Inconel 600 and 690 in pure water

P. Zhang et al.

Summary: The fretting wear behaviors of Inconel 600 and 690 plates against 304 stainless steel ball were studied in pure water, with Inconel 600 showing better wear resistance due to fewer fatigue cracks formation caused by its lower chromium content. The formation of fatigue cracks was explained to be mainly at the interface of Ni-rich zone/Cr-rich oxides zone in the transformed structure during fretting wear. The higher chromium content in Inconel 690 promoted the formation of fatigue cracks by increasing the area of Cr-rich oxides zone.
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Characterization and machining performance of a chipping resistant ultra-soft coating used for the machining of Inconel 718

Saharnaz Montazeri et al.

Summary: Inconel 718 is widely used in the aerospace industry due to its excellent mechanical properties, but its poor machinability remains a major challenge. This study shows that depositing a soft Al-Si coating on a cutting tool significantly improves performance during Inconel 718 machining. By optimizing deposition parameters, the Al-Si coating enhances tool life and reduces cutting force, surpassing traditional hard coatings.
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Characterization of Inconel 718® superalloy fabricated by wire Arc Additive Manufacturing: effect on mechanical properties and machinability

Unai Alonso et al.

Summary: Wire and Arc Additive Manufacturing is a promising technology for producing large metallic parts, but post-processing machining is still necessary. This study investigated the microstructure and mechanical properties of Inconel 718 walls and explored the effects of cutting speed and machining direction on slot milling operations. Higher cutting speeds result in better surface quality and lower torques, with milling along the torch's travel direction offering better dimensional tolerance values and lower cutting torques.

JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T (2021)

Proceedings Paper Materials Science, Multidisciplinary

Influence of variation in cutting velocity on temperature, surface finish, chip form and insert after dry turning Inconel 600 with TiAlN carbide insert

M. Dhananchezian

Summary: Inconel 600, known for its high hardness, resistance to corrosion and oxidation, is considered difficult to cut. This study examined the effects of cutting speed on temperature, surface finish, insert and chip form during turning of Inconel 600 using TiAlN coated cutting insert. The lowest surface roughness was achieved at a cutting velocity of 102 m/min, with chip adhesion observed at lower cutting velocities of 25, 38 and 62 m/min. Long and continuous chips were obtained in all cutting trials.

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Application of Taguchi method on Wire Electrical Discharge Machining of Inconel 625

N. Manikandan et al.

Summary: This study focuses on optimizing the process parameters for machining Inconel 625 using Taguchi's analysis in WEDM, in order to overcome the limitations of traditional machining methods.

MATERIALS TODAY-PROCEEDINGS (2021)

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Experimental Investigation and Parametric Optimization on Hole Quality Assessment During Micro-drilling of Inconel 625 Superalloy

K. Venkatesan et al.

Summary: The experimental study on micro-drilling of Inconel 625 presents the effects of tool diameter, spindle speed, and feed rate on hole quality assessment. The optimal combination for achieving high quality holes is high tool diameter, low speed, and high feed rate. The most suitable tool diameter for hole quality and productivity is found to be 0.8mm.

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