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Heat-assisted machining of superalloys: a review

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Abstract

Superalloys are vastly used in the aerospace industry due to their alluring properties such as maintaining their strength at high-temperature applications. Nevertheless, manufacturing these raw materials to the desired geometrical shapes is one of the main challenges of the subtractive manufacturing industry and they are categorized as hard-to-machine materials. Several approaches such as high-speed machining (HSM), cryogenic cooling, minimum quantity lubrication (MQL), and heat-assisted machining (HAM) are introduced to tackle this matter.

HAM is a technique that introduces external heat sources to the workpiece (pre-heating or real-time heating methods) to increase the ductility of the superalloy and therefore reduce the yield and shear strength of the workpiece. By this means, the machining parameters demonstrate an improvement compared to conventional machining.

This review article focuses on the research approaches conducted to evaluate the effect of the various heat source applications (gas flame, induction, laser, and plasma) on the material properties and the machinability of the superalloys. Additionally, the heating methodology and heat assistance impact on cutting parameters (forces, tool life, surface integrity, and chip morphology) are outlined. Finally, a comparison of the heat source efficiency and the economics of the various heat applications is performed.

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Data availability

The authors confirm that the data supporting the findings of this study are available within the article.

Abbreviations

\(\alpha\) :

Beam divergence

\(\Delta t\) :

Pulse duration

\(\varepsilon\) :

Electrical permittivity

\(\eta\) :

Thermal efficiency

\(\mu\) :

Magnetic Permeability

\(\rho\) :

Electrical Resistivity

\({\rho }_{t}\) :

Density

\(\sigma\) :

Electrical Conductivity

\(b\) :

Width of Cut

\(C\) :

Specific heat

\({d}_{s}\) :

Laser spot diameter

\(D\) :

Diameter

\(\overline{D }\) :

Electric flux density

\({f}_{r}\) :

Feed per revolution

\({F}_{f}\) :

Feed Force

\({F}_{l}\) :

Focal length of the lens

\({F}_{r}\) :

Radial Force

\({F}_{t}\) :

Tangential Force

\(h\) :

Depth of Cut

\({T}_{s}\) :

Surface thermal

\(V\) :

Voltage

\(\overline{H }\) :

Magnetic field intensity

\(i\) :

Inclination angle

\(I\) :

Current

\(\overline{J }\) :

Current Density

\(k\) :

Thermal conductivity

\({K}_{fc}\) :

Feed Cutting Constant

\({K}_{fe}\) :

Feed Edge Constant

\({K}_{rc}\) :

Radial Cutting Constant

\({K}_{re}\) :

Radial Edge Constant

\({K}_{tc}\) :

Tangential Cutting Constant

\({K}_{te}\) :

Tangential Edge Constant

\({L}_{p}\) :

Laser power

\({P}_{d}\) :

Power density

\(q\) :

Heat generation rate

\(Q\) :

Input power

\(r\) :

Radius

\(t\) :

Time

\(T\) :

Temperature

\({T}_{0}\) :

Initial thermal

\({V}_{c}\) :

Cutting speed/Velocity

\(x\) :

Length in cutting direction

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Authors and Affiliations

  1. Mechanical Engineering Department, School of Engineering and Natural Sciences, Altinbas University, Istanbul, Turkey

    Armin Bijanzad, Talha Munir & Farouk Abdulhamid

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  1. Armin Bijanzad
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  2. Talha Munir
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  3. Farouk Abdulhamid
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Bijanzad, A., Munir, T. & Abdulhamid, F. Heat-assisted machining of superalloys: a review. Int J Adv Manuf Technol 118, 3531–3557 (2022). https://doi.org/10.1007/s00170-021-08059-2

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