Skip to main content
SpringerLink
Log in

Understanding the machining induced tribological mechanism of Hastelloy-X under sustainable cooling/lubrication conditions

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Despite the recent developments in non-conventional manufacturing approaches, machining is still a prominent technique for the mass production of metallic components. However, given the difficult-to-machine nature and high heat generation during machining of Hastelloy-X, there is a lack of comparative investigations that can provide basics for sustainable process management in machining of Hastelloy-X. Different sustainable cooling approaches (dry, minimum quantity lubrication (MQL), cryogenic) and their impact on Hastelloy-X machining process behavior have been investigated in this study. Machining parameters such as constant cutting speed of 124 mm/min, feed rate of 0.15 mm/min, and cutting depth of 0.1 mm and cutting force, cutting temperature, and surface roughness were consider as output responses. It was observed that with the adaptation of cryogenic conditions, cutting forces can be reduced 5 to 14% in comparison with MQL and dry conditions. Cutting temperature and surface roughness values were however observed to be largely reduced with cryogenic cooling. The chipping and adhesion were found to be reduced with cryogenic cooling due to the reduction in workpiece softening behavior and increase in hardness to cutting tool.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

Availability of data and material

Not applicable.

Code availability

Not applicable.

References

  1. Mazur Z, Luna-Ramirez A, Juárez-Islas JA, Campos-Amezcua A (2005) Failure analysis of a gas turbine blade made of Inconel 738LC alloy. Eng Fail Anal 12:474–486

    Article  Google Scholar 

  2. Parida AK, Maity K (2018) Comparison the machinability of Inconel 718, Inconel 625 and Monel 400 in hot turning operation. Eng Sci Technol an Int J 21:364–370. https://doi.org/10.1016/J.JESTCH.2018.03.018

    Article  Google Scholar 

  3. Han Q, Mertens R, Montero-Sistiaga ML et al (2018) Laser powder bed fusion of Hastelloy X: effects of hot isostatic pressing and the hot cracking mechanism. Mater Sci Eng A 732:228–239

    Article  Google Scholar 

  4. Kadirgama K, Abou-El-Hossein KA, Noor MM et al (2011) Tool life and wear mechanism when machining Hastelloy C-22HS. Wear 270:258–268. https://doi.org/10.1016/J.WEAR.2010.10.067

    Article  Google Scholar 

  5. Günay M, Korkmaz ME, Yaşar N (2020) Performance analysis of coated carbide tool in turning of Nimonic 80A superalloy under different cutting environments. J Manuf Process 56:678–687. https://doi.org/10.1016/j.jmapro.2020.05.031

    Article  Google Scholar 

  6. Korkmaz ME, Yaşar N, Günay M (2020) Numerical and experimental investigation of cutting forces in turning of Nimonic 80A superalloy. Eng Sci Technol Int J 23:664–673. https://doi.org/10.1016/j.jestch.2020.02.001

    Article  Google Scholar 

  7. Sivaiah P, Chakradhar D (2018) Effect of cryogenic coolant on turning performance characteristics during machining of 17–4 PH stainless steel: a comparison with MQL, wet, dry machining. CIRP J Manuf Sci Technol 21:86–96. https://doi.org/10.1016/j.cirpj.2018.02.004

    Article  Google Scholar 

  8. Sivaiah P, Chakradhar D (2019) Performance improvement of cryogenic turning process during machining of 17–4 PH stainless steel using multi objective optimization techniques. Measurement 136:326–336. https://doi.org/10.1016/j.measurement.2018.12.094

    Article  Google Scholar 

  9. Ullah I, Zhang S, Waqar S (2022) Numerical and experimental investigation on thermo-mechanically induced residual stress in high-speed milling of Ti-6Al-4V alloy. J Manuf Process 76:575–587

    Article  Google Scholar 

  10. Waqar S, Asad S, Ahmad S et al (2017) Effect of drilling parameters on hole quality of Ti-6Al-4V titanium alloy in dry drilling. In: Materials science forum. Trans Tech Publ 33−36

  11. Demirsöz R, Boy M (2022) Measurement and evaluation of machinability characteristics in turning of train wheel steel via CVD coated-RCMX carbide tool. Manuf Technol Appl 3:1−13. https://doi.org/10.52795/mateca.1058771

  12. Guo B, Zhang Y, He F, Ma J, Li J, Wang Z, Wang J, Feng J, Wang W, Gao L (2021) Origins of the mechanical property heterogeneity in a hybrid additive manufactured Hastelloy X. Mater Sci Eng A 823:141716

    Article  Google Scholar 

  13. Dhananchezian M (2019) Study the machinability characteristics of nicked based Hastelloy C-276 under cryogenic cooling. Measurement 136:694–702. https://doi.org/10.1016/j.measurement.2018.12.072

    Article  Google Scholar 

  14. Ding Q, Bei H, Wei X, Gao YF, Zhang Z (2021) Nano-twin-induced exceptionally superior cryogenic mechanical properties of a Ni-based GH3536 (Hastelloy X) superalloy. Mater Today Nano 14:100110

    Article  Google Scholar 

  15. Huang E-W, Clausen B, Wang Y, Choo H, Liaw PK, Benson ML, Pike LM, Klarstrom DL (2007) A neutron-diffraction study of the low-cycle fatigue behavior of HASTELLOY® C-22HSTM alloy. Int J Fatigue 29:1812–1819

    Article  Google Scholar 

  16. Caiazzo F, Corrado G, Alfieri VG, Alfieri V, Sergi V, Cuccaro L (2013) Disk-laser welding of Hastelloy X cover on René 80 turbine stator blade. In: XIX International Symposium on High-Power Laser Systems and Applications 2012. SPIE, pp 172–181

  17. Shindo M, Nakajima H (1989) Evaluation of Al2O3 and TiN coating on Hastelloy XR alloy under aggressive conditions. ISIJ Int 29:793–795

    Article  Google Scholar 

  18. Sivalingam V, Sun J, Selvam B, Murugasen PK, Yang B, Waqar S (2019) Experimental investigation of tool wear in cryogenically treated insert during end milling of hard Ti alloy. J Brazilian Soc Mech Sci Eng 41:110

    Article  Google Scholar 

  19. Waqar S, He Y, Abbas CA, Majeed A (2017) Optimization of cutting tool geometric parameters in milling of CFRP laminates

  20. Çakır Şencan A, Çelik M, Selayet Saraç EN (2021) The effect of nanofluids used in the MQL technique applied in turning process on machining performance: a review on eco-friendly machining. Manuf Technol Appl 2:47–66. https://doi.org/10.52795/mateca.1020081

  21. Kadirgama K, Abou-El-Hossein KA, Mohammad B et al (2008) Cutting force prediction model by FEA and RSM when machining Hastelloy C-22HS with 90 holder

  22. Khidhir BA, Mohamed B (2011) Analyzing the effect of cutting parameters on surface roughness and tool wear when machining nickel based Hastelloy–276. In: IOP conference series: materials science and engineering. IOP Publishing, p 12043

  23. Dhananchezian M, Rajkumar K (2020) Comparative study of cutting insert wear and roughness parameter (Ra) while turning Nimonic 90 and hastelloy C-276 by coated carbide inserts. Mater Today Proc 22:1409–1416

    Article  Google Scholar 

  24. Palanisamy S, McDonald SD, Dargusch MS (2009) Effects of coolant pressure on chip formation while turning Ti6Al4V alloy. Int J Mach Tools Manuf 49:739–743. https://doi.org/10.1016/j.ijmachtools.2009.02.010

    Article  Google Scholar 

  25. Mia M, Dhar NR (2018) Effects of duplex jets high-pressure coolant on machining temperature and machinability of Ti-6Al-4V superalloy. J Mater Process Technol 252:688–696. https://doi.org/10.1016/j.jmatprotec.2017.10.040

    Article  Google Scholar 

  26. Danish M, Ginta TL, Habib K, Abdul Rani AM, Saha BB (2019) Effect of cryogenic cooling on the heat transfer during turning of AZ31C magnesium alloy. Heat Transf Eng 40:1023–1032. https://doi.org/10.1080/01457632.2018.1450345

    Article  Google Scholar 

  27. Danish M, Ginta TL, Habib K, Carou D, Rani AMA, Saha BB (2017) Thermal analysis during turning of AZ31 magnesium alloy under dry and cryogenic conditions. Int J Adv Manuf Technol 91:2855–2868. https://doi.org/10.1007/s00170-016-9893-5

    Article  Google Scholar 

  28. Yurtkuran H (2021) An evaluation on machinability characteristics of titanium and nickel based superalloys used in aerospace industry. Manuf Technol Appl 2:10–29. https://doi.org/10.52795/mateca.940261

  29. Sharma VS, Singh G, Sørby K (2015) A review on minimum quantity lubrication for machining processes. Mater Manuf Process. https://doi.org/10.1080/10426914.2014.994759

    Article  Google Scholar 

  30. Singh H, Sharma VS, Dogra M (2020) Exploration of graphene assisted vegetables oil based minimum quantity lubrication for surface grinding of TI-6AL-4V-ELI. Tribol Int 144:106113

    Article  Google Scholar 

  31. Sharma VS, Dogra M, Suri NM (2009) Cooling techniques for improved productivity in turning. Int J Mach Tools Manuf 49:435–453. https://doi.org/10.1016/j.ijmachtools.2008.12.010

    Article  Google Scholar 

  32. Balan AS, Vijayaraghavan L, Krishnamurthy R (2013) Minimum quantity lubricated grinding of Inconel 751 alloy. Mater Manuf Process 28:430–435. https://doi.org/10.1080/10426914.2013.763965

    Article  Google Scholar 

  33. Venkatesan K, Devendiran S, Nishanth Purusotham K, Praveen VS (2020) Study of machinability performance of Hastelloy-X for nanofluids, dry with coated tools. Mater Manuf Process 35:751–761

    Article  Google Scholar 

  34. Dhar NR, Islam MW, Islam S, Mithu MAH (2006) The influence of minimum quantity of lubrication (MQL) on cutting temperature, chip and dimensional accuracy in turning AISI-1040 steel. J Mater Process Technol 171:93–99

    Article  Google Scholar 

  35. Liu ZQ, Cai XJ, Chen M, An QL (2011) Investigation of cutting force and temperature of end-milling Ti-6Al-4V with different minimum quantity lubrication (MQL) parameters. Proc Inst Mech Eng Part B J Eng Manuf 225:1273–1279. https://doi.org/10.1177/2041297510393793

    Article  Google Scholar 

  36. Le Coz G, Marinescu M, Devillez A, Dudzinski D, Velnom L (2012) Measuring temperature of rotating cutting tools: application to MQL drilling and dry milling of aerospace alloys. Appl Therm Eng 36:434–441. https://doi.org/10.1016/j.applthermaleng.2011.10.060

    Article  Google Scholar 

  37. Sharma AK, Tiwari AK, Dixit AR (2015) Progress of nanofluid application in machining: a review. Mater Manuf Process 30:813–828. https://doi.org/10.1080/10426914.2014.973583

    Article  Google Scholar 

  38. Yıldırım ÇV (2019) Experimental comparison of the performance of nanofluids, cryogenic and hybrid cooling in turning of Inconel 625. Tribol Int 137:366–378. https://doi.org/10.1016/j.triboint.2019.05.014

    Article  Google Scholar 

  39. Jebaraj M, Pradeep Kumar M (2019) Effect of cryogenic CO2 and LN2 coolants in milling of aluminum alloy. Mater Manuf Process 34:511–520

    Article  Google Scholar 

  40. Song C, Liu Q, Deng S, Li H, Kitamura Y (2019) Cryogenic-based CO2 capture technologies: state-of-the-art developments and current challenges. Renew Sustain Energy Rev 101:265–278

    Article  Google Scholar 

  41. Rotella G, Dillon OW, Umbrello D, Settineri L, Jawahir IS (2014) The effects of cooling conditions on surface integrity in machining of Ti6Al4V alloy. Int J Adv Manuf Technol 71:47–55. https://doi.org/10.1007/s00170-013-5477-9

    Article  Google Scholar 

  42. Mia M, Gupta MK, Lozano JA, Carou D, Pimenov DY, Królczyk G, Khan AM, Dhar NR (2019) Multi-objective optimization and life cycle assessment of eco-friendly cryogenic N2 assisted turning of Ti-6Al-4V. J Clean Prod 210:121–133. https://doi.org/10.1016/j.jclepro.2018.10.334

    Article  Google Scholar 

  43. Hong SY, Ding Y, Jeong W (2001) Friction and cutting forces in cryogenic machining of Ti – 6Al – 4V. Int J Mach Tools Manuf 41:2271–2285

    Article  Google Scholar 

  44. Khanna N, Agrawal C, Pimenov DY, Singla AK, Machado AR, da Silva LR, Gupta MK, Sarikaya M, Krolczyk GM (2021) Review on design and development of cryogenic machining setups for heat resistant alloys and composites. J Manuf Process 68:398–422. https://doi.org/10.1016/j.jmapro.2021.05.053

    Article  Google Scholar 

  45. Hong SY, Markus I, Jeong WC (2001) New cooling approach and tool life improvement in cryogenic machining of titanium alloy Ti-6Al-4V. Int J Mach Tools Manuf 41:2245–2260. https://doi.org/10.1016/S0890-6955(01)00041-4

    Article  Google Scholar 

Download references

Funding

This work is supported by the Fundamental Research Funds of Shandong University (2019HW040) and the Future for Young Scholars of Shandong University, China (31360082064026).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Key Laboratory of High-Efficiency and Clean Mechanical Manufacture, National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, 250061, China

    Qian Zhou, Vinothkumar Sivalingam & Jie Sun

  2. Research Centre for Aeronautical Component Manufacturing Technology & Equipment, Jinan, China

    Qian Zhou, Vinothkumar Sivalingam & Jie Sun

  3. Department of Mechanical Engineering, CEG, Anna University, Chennai, 600025, India

    Pradeep Kumar Murugasen

  4. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758, Opole, Poland

    Munish Kumar Gupta

  5. Department of Mechanical Engineering, Karabük University, Karabük, Turkey

    Mehmet Erdi Korkmaz

Authors
  1. Qian Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Vinothkumar Sivalingam
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jie Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Pradeep Kumar Murugasen
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Munish Kumar Gupta
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Mehmet Erdi Korkmaz
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Qian Zhou: experimental work and data curation writing—review and editing. Vinothkumar Sivalingam: conceptualization, supervision; experimental work; funding and data curation writing—review and editing; and technical validation. Jie Sun: project administration, resources and supervision. Pradeep kumar Murugasen: formal analysis, writing—review and editing. Munish Kumar Gupta: writing—review and editing; and visualization. Mehmet Erdi Korkmaz: writing—review; validation and editing.

Corresponding authors

Correspondence to Vinothkumar Sivalingam or Jie Sun.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

Not applicable.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhou, Q., Sivalingam, V., Sun, J. et al. Understanding the machining induced tribological mechanism of Hastelloy-X under sustainable cooling/lubrication conditions. Int J Adv Manuf Technol 123, 973–983 (2022). https://doi.org/10.1007/s00170-022-10243-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10243-x

Keywords

Search

Navigation