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Overcoming machining challenges in hybrid laser metal deposition of IN718 with heat-assisted minimum quantity lubrication

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Abstract

This study addresses machining challenges in hybrid additive manufacturing, specifically focusing on laser metal deposition on wire arc additively manufactured substrates. Under identical conditions of laser metal deposition, we identify significant differences in machinability between wire arc additively manufactured and cold-rolled substrates. Hybrid laser-wire deposition, particularly IN718 on wire arc additively manufactured steel substrate, exhibits increased cutting forces, elevated surface roughness, heightened tool wear, tool breakage, and chatter during machining attributed to increased hardness along the build direction, influenced by substrate type and thermal conductivities. To mitigate these challenges, we propose a novel heat-assisted minimum quantity lubrication (air + oil aerosol) approach. Pre-heating the material and applying minimal lubrication during machining reduces cutting forces by ~ 26%, surface roughness by ~ 60%, and tool wear by ~ 67% compared to dry machining, due to increased temperature ductility of IN718, and enhanced cooling caused by minimum quantity lubrication. These findings underscore the effectiveness of pre-heating in improving machining outcomes across diverse process parameters.

Highlights

  • Explored additive-subtractive challenges in hybrid laser metal deposition of IN718

  • Significantly altered machinability of HLMDed IN718 compared to LMDed counterpart

  • Heat-assisted machining significantly enhances HLMDed IN718 machinability

  • Substrate proximity affects machinability leading to higher forces and variability

  • Machining outputs less sensitive to deposition conditions in heat-assisted machining

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Acknowledgements

The authors acknowledge the support of Oleksandr Kurtov and Fereidoon Marefat for experimental support.

Author information

Authors and Affiliations

  1. Department of Materials Engineering, KU Leuven, Campus De Nayer, 2860, Sint-Katelijne Waver, Belgium

    Angshuman Kapil, Ozan Can Ozaner & Abhay Sharma

  2. Joining and Welding Research Institute, Osaka University, Osaka, Japan

    Yuji Sato, Yoshihiko Hayashi, Keiichiro Ikeda, Tetsuo Suga & Masahiro Tsukamoto

  3. Department of Mechanical Program, Hacettepe University, 06930, Ankara, Turkey

    Sener Karabulut & Musa Bilgin

  4. Department of Mechanical, Aerospace and Civil Engineering, The University of Manchester, Manchester, UK

    Musa Bilgin

  5. Department of Mechanical Engineering, Indian Institute of Technology Jammu, Jammu, 181221, India

    Abhay Sharma

Authors
  1. Angshuman Kapil
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  2. Ozan Can Ozaner
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  4. Yoshihiko Hayashi
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  9. Musa Bilgin
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Contributions

Angshuman Kapil: formal analysis, investigation, methodology, visualization, writing–original draft. Ozan Can Ozaner: formal analysis, investigation, methodology, writing–review and editing. Yuji Sato: conceptualization, investigation, methodology. Yoshihiko Hayashi: investigation, methodology. Keiichiro Ikeda: investigation, methodology. Tetsuo Suga: funding acquisition, project administration. Masahiro Tsukamoto: project administration, resources. Sener Karabulut: investigation, methodology. Musa Bilgin: investigation, methodology. Abhay Sharma: conceptualization, funding acquisition, methodology, project administration, resources, supervision, writing–review and editing.

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Correspondence to Abhay Sharma.

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Appendix

Appendix

Fig. 14
figure 14

Representative images of the cutting tools that broke at the edges during dry machining of HLMDed IN718 walls

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Figure 15a shows a magnified image of the built-up edge (BUE) depicted in Fig. 5b. An energy dispersive spectroscopy (EDS) area scan performed on the BUE (region marked in Fig. 15a) indicates the presence of a high amount of Ni. Considering that the tool material does not contain Ni and IN718 contains a high amount of Ni, it is determined that the area indicated in Fig. 15a is a (BUE) formation.

Fig. 15
figure 15

a Microscopic image of the built-up-edge formed during dry machining of HLMDed IN718 wall, and b results of the EDS area scan performed on the built-up-edge

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Kapil, A., Ozaner, O.C., Sato, Y. et al. Overcoming machining challenges in hybrid laser metal deposition of IN718 with heat-assisted minimum quantity lubrication. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13646-0

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