Abstract
Surface integrity is considered to be a significant factor in evaluating surface qualities. A wide range of applications of nickel-based superalloys can be attributed to a number of features such as mechanical and chemical characteristics at elevated temperatures, high durability and ductileness, great resistance to corrosion, high melting point, thermal shock, thermal fatigue, and erosion. However, the practical performance of the component particularly the fatigue life is critically influenced by the machined surface finish of Ni-based superalloys. The present review article provides the most recent information on various surface integrity properties while machining Ni-based superalloys. The surface integrity aspects contain the surface topography including machined surface defects (plucking, metal debris, feed marks, surface cavities, smeared material, grooves and laps, cracking, carbide particles, and redeposited materials) and surface roughness; the metallurgical phase consists of plasticity, grain refinement and orientation, and white layer formation, and mechanical characteristics comprise the residual stress and strain hardening. The impact of various cutting parameters, the cutting environment, and cutting tool materials have been carefully explained on surface metallurgy and mechanical characteristics. Moreover, the influence of surface integrity on the fatigue life of machined components has been studied.
Similar content being viewed by others
Abbreviations
- Vc:
-
Cutting force
- f:
-
Feed
- ap :
-
Axial depth of cut
- ae :
-
Radial depth of cut
- MQL:
-
Minimum quantity lubrication
- BUE:
-
Built-up edge
- SEM:
-
Scanning electron microscope
- VBmax :
-
Flank wear
- XRD:
-
Xray diffraction
- ESBD:
-
Electron backscattered diffraction
- TEM:
-
Transmission electron microscopy
- PVD:
-
Physical vapor deposition
- CVD:
-
Chemical vapor deposition
- CBN:
-
Carbon boron nitride
- DRX:
-
Dynamic recrystallization
- EBS:
-
Electron backscattered
References
Mustafa G, Anwar MT, Ahmed A, Nawaz M, Rasheed T (2022) Influence of machining parameters on machinability of Inconel 718—a review. Adv Eng Mater 24:1–17. https://doi.org/10.1002/adem.202200202
Zhu D, Zhang X, Ding H (2013) Tool wear characteristics in machining of nickel-based superalloys. Int J Mach Tools Manuf 64:60–77. https://doi.org/10.1016/j.ijmachtools.2012.08.001
Çelik A, Sert Alağaç M, Turan S, Kara A, Kara F (2017) Wear behavior of solid SiAlON milling tools during high speed milling of Inconel 718. Wear 378–379:58–67. https://doi.org/10.1016/j.wear.2017.02.025
Mustafa G, Liu J, Zhang F, Wang G, Yang Z, Harris M, Liu S, Liu X, Jin Z, Sun J (2019) Atmospheric pressure plasma jet assisted micro-milling of Inconel 718. Int J Adv Manuf Technol 103:4681–4687. https://doi.org/10.1007/s00170-019-03931-8
Ezugwu EO, Tang SH (1995) Surface abuse when machining cast iron (G-17) and nickel-base superalloy (Inconel 718) with ceramic tools. J Mater Process Technol 55:63–69. https://doi.org/10.1016/0924-0136(95)01786-0
Ulutan D, Ozel T (2011) Machining induced surface integrity in titanium and nickel alloys: a review. Int J Mach Tools Manuf 51:250–280. https://doi.org/10.1016/j.ijmachtools.2010.11.003
Hardy MC, Herbert CRJ, Kwong J, Li W, Axinte DA (2014) Characterising the integrity of machined surfaces in a powder nickel alloy used in aircraft engines. Procedia CIRP 13:411–416. https://doi.org/10.1016/j.procir.2014.04.070
Parida AK, Maity K (2017) Effect of nose radius on forces, and process parameters in hot machining of Inconel 718 using finite element analysis. Eng Sci Technol an Int J 20:687–693. https://doi.org/10.1016/j.jestch.2016.10.006
Ghiban B, Elefterie CF, Guragata C, Bran D (2018) Requirements of Inconel 718 alloy for aeronautical applications, p 030016
Özel T, Arisoy YM (2014) Experimental and numerical investigations on machining induced surface integrity in inconel-100 nickel-base alloy. Procedia CIRP 13:302–307. https://doi.org/10.1016/j.procir.2014.04.051
Fan YH, Hao ZP, Zheng ML et al (2013) Study of surface quality in machining nickel-based alloy Inconel 718. Int J Adv Manuf Technol 69:2659–2667. https://doi.org/10.1007/s00170-013-5225-1
Dowling AP, Mahmoudi Y (2015) Combustion noise Proc Combust Inst 35:65–100. https://doi.org/10.1016/j.proci.2014.08.016
Patel SJ (2006) A century of discoveries, inventors, and new nickel alloys. Jom 58:18–20. https://doi.org/10.1007/s11837-006-0076-y
Guo Y, Klink A, Fu C, Snyder J (2013) Machinability and surface integrity of nitinol shape memory alloy. CIRP Ann - Manuf Technol 62:83–86. https://doi.org/10.1016/j.cirp.2013.03.004
Cui C, Hu BM, Zhao L, Liu S (2011) Titanium alloy production technology, market prospects and industry development. Mater Des 32:1684–1691. https://doi.org/10.1016/j.matdes.2010.09.011
Zhang LC, Attar H (2016) Selective laser melting of titanium alloys and titanium matrix composites for biomedical applications: a review. Adv Eng Mater 18:463–475. https://doi.org/10.1002/adem.201500419
Thakur A, Gangopadhyay S, Maity KP (2014) Effect of cutting speed and CVD multilayer coating on machinability of Inconel 825. Surf Eng 30:516–523. https://doi.org/10.1179/1743294414Y.0000000274
Pramanik A, Littlefair G (2015) Machining of titanium alloy (Ti-6Al-4V) —theory to application. Mach Sci Technol 19:1–49. https://doi.org/10.1080/10910344.2014.991031
Thakur A, Gangopadhyay S, Mohanty A (2015) Investigation on some machinability aspects of Inconel 825 during dry turning. Mater Manuf Process 30:1026–1034. https://doi.org/10.1080/10426914.2014.984216
Sravan Sashank S, Rajakumar S, Karthikeyan R, Nagaraju DS (2020) Weldability, mechanical properties and microstructure of nickel based super alloys: a review. E3S Web Conf 184:1–6. https://doi.org/10.1051/e3sconf/202018401040
Li ZY, Wei XT, Guo YB, Sealy MP (2015) State-of-art, challenges, and outlook on manufacturing of cooling holes for turbine blades. Mach Sci Technol 19:361–399. https://doi.org/10.1080/10910344.2015.1051543
Biermann D, Kersting P, Surmann T (2010) A general approach to simulating workpiece vibrations during five-axis milling of turbine blades. CIRP Ann - Manuf Technol 59:125–128. https://doi.org/10.1016/j.cirp.2010.03.057
Thakur A, Gangopadhyay S (2016) State-of-the-art in surface integrity in machining of nickel-based super alloys. Int J Mach Tools Manuf 100:25–54. https://doi.org/10.1016/j.ijmachtools.2015.10.001
Wang B, Liu Z (2018) Influences of tool structure, tool material and tool wear on machined surface integrity during turning and milling of titanium and nickel alloys: a review. Int J Adv Manuf Technol 98:1925–1975. https://doi.org/10.1007/s00170-018-2314-1
Iturbe A, Hormaetxe E, Garay A, Arrazola PJ (2016) Surface Integrity analysis when machining Inconel 718 with conventional and cryogenic cooling. Procedia CIRP 45:67–70. https://doi.org/10.1016/j.procir.2016.02.095
Cantero JL, Díaz-Álvarez J, Miguélez MH, Marín NC (2013) Analysis of tool wear patterns in finishing turning of Inconel 718. Wear 297:885–894. https://doi.org/10.1016/j.wear.2012.11.004
Pervaiz S, Rashid A, Deiab I, Nicolescu M (2014) Influence of tool materials on machinability of titanium- and nickel-based alloys: a review. Mater Manuf Process 29:219–252. https://doi.org/10.1080/10426914.2014.880460
Davim JP (2010) Surface integrity in machining. Springer, London, London
Natarajan SK, Prakash R, Sankaranarayanasamy K (2022) Recent advances in manufacturing, automation, design and energy technologies. Springer Singapore, Singapore
Yin X, Li X, Liu Y, Geng D, Zhang D (2023) Surface integrity and fatigue life of Inconel 718 by ultrasonic peening milling. J Mater Res Technol 22:1392–1409. https://doi.org/10.1016/j.jmrt.2022.12.019
Tu L, Ming W, Xu X, Cai C, Chen J, An Q, Xu J, Chen M (2022) Wear and failure mechanisms of SiAlON ceramic tools during high-speed turning of nickel-based superalloys. Wear 488–489:204171. https://doi.org/10.1016/j.wear.2021.204171
Huang X, Shi K, Zheng S (2022) Research on the surface integrity and fatigue behavior of grinding Ni-based superalloy GH4169DA. 2022 13th Int Conf Mech Aerosp Eng ICMAE 2022 13–20. https://doi.org/10.1109/ICMAE56000.2022.9852865
Xiao G, Chen B, Li S, Zhuo X, Zhao Z (2022) Surface integrity and fatigue performance of GH4169 superalloy using abrasive belt grinding. Eng Fail Anal 142:. https://doi.org/10.1016/j.engfailanal.2022.106764
Masood Arif Bukhari S, Husnain N, Arsalan Siddiqui F, Anwar MT (2023) Effect of laser surface remelting on microstructure, mechanical properties and tribological properties of metals and alloys: a review. Opt Laser Technol 165:. https://doi.org/10.1016/j.optlastec.2023.109588
Singh R, Sharma V (2022) Machining induced surface integrity behavior of nickel-based superalloy: effect of lubricating environments. J Mater Process Technol 307:117701. https://doi.org/10.1016/j.jmatprotec.2022.117701
Beck RJ, Aspinwall DK, Soo SL, Williams P, Perez R (2022) Fatigue performance of surface ground and wire electrical discharge machined TiNi shape memory alloy. Proc Inst Mech Eng Part B J Eng Manuf 236:355–362. https://doi.org/10.1177/09544054211028844
Madariaga A, Garay A, Esnaola JA, Arrazola PJ (2022) Effect of surface integrity generated by machining on isothermal low cycle fatigue performance of Inconel 718. Eng Fail Anal 137:. https://doi.org/10.1016/j.engfailanal.2022.106422
Chen Z, Huang C, Li B, Jiang G, Tang Z, Niu J, Liu H (2022) Experimental study on surface integrity of Inconel 690 milled by coated carbide inserts. Int J Adv Manuf Technol 121:3025–3042. https://doi.org/10.1007/s00170-022-09456-x
Ardi DT, Li YG, Chan KHK, Bache MR (2014) Surface roughness, areal topographic measurement, and correlation to LCF behavior in a nickel-based superalloy. J Mater Eng Perform 23:3657–3665. https://doi.org/10.1007/s11665-014-1130-5
Tan L, Yang XG, Shi DQ, Hao WQ, Fan YS (2022) Unified fatigue life modelling and uncertainty estimation of Ni-based superalloy family with a supervised machine learning approach. Eng Fract Mech 275:. https://doi.org/10.1016/j.engfracmech.2022.108813
Xiao G, Chen B, Li S, Zhuo X (2022) Fatigue life analysis of aero-engine blades for abrasive belt grinding considering residual stress. Eng Fail Anal 131:1–14. https://doi.org/10.1016/j.engfailanal.2021.105846
Kumar D, Idapalapati S, Wang W (2021) Influence of residual stress distribution and microstructural characteristics on fatigue failure mechanism in Ni-based superalloy. Fatigue Fract Eng Mater Struct 44:1583–1601. https://doi.org/10.1111/ffe.13454
Zhu L, Fan X, Xiao L, Ji H, Guo J (2023) Influence of shot peening on the microstructure and high-temperature tensile properties of a powder metallurgy Ni-based superalloy. J Mater Sci 58:2838–2852. https://doi.org/10.1007/s10853-023-08182-3
Liu SY, Shao S, Guo H, Zong R, Qin CX (2022) The microstructure and fatigue performance of Inconel 718 produced by laser-based powder bed fusion and post heat treatment. Int J Fatigue 156:. https://doi.org/10.1016/j.ijfatigue.2021.106700
Shokrani A, Dhokia V, Newman ST (2012) Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids. Int J Mach Tools Manuf 57:83–101. https://doi.org/10.1016/j.ijmachtools.2012.02.002
Ulutan D, Sima M, Özel T (2011) Prediction of machining induced surface integrity using elastic-viscoplastic simulations and temperature-dependent flow softening material models in titanium and nickel-based alloys. Adv Mater Res 223:401–410. https://doi.org/10.4028/www.scientific.net/AMR.223.401
Soo SL, Aspinwall DK, Dewes RC (2004) Three-dimensional finite element modelling of high-speed milling of Inconel 718. Proc Inst Mech Eng Part B J Eng Manuf 218:1555–1561. https://doi.org/10.1243/0954405042418473
Aspinwall DK, Soo SL, Berrisford AE, Walder G (2008) Workpiece surface roughness and integrity after WEDM of Ti-6Al-4V and Inconel 718 using minimum damage generator technology. CIRP Ann - Manuf Technol 57:187–190. https://doi.org/10.1016/j.cirp.2008.03.054
Attia H, Tavakoli S, Vargas R, Thomson V (2010) Laser-assisted high-speed finish turning of superalloy Inconel 718 under dry conditions. CIRP Ann - Manuf Technol 59:83–88. https://doi.org/10.1016/j.cirp.2010.03.093
Axinte DA, De Chiffre L (2008) Effectiveness and resolution of tests for evaluating the performance of cutting fluids in machining aerospace alloys. CIRP Ann - Manuf Technol 57:129–132. https://doi.org/10.1016/j.cirp.2008.03.081
Axinte D, Axinte M, Tannock JDT (2003) A multicriteria model for cutting fluid evaluation. Proc Inst Mech Eng Part B J Eng Manuf 217:1341–1353. https://doi.org/10.1243/095440503322617117
Figiel H, Zogał O, Yartys V (2005) Journal of alloys and compounds: preface. J Alloys Compd 404–406:1. https://doi.org/10.1016/j.jallcom.2005.05.002
Li DS, Chen G, Li D, Zheng Q, Gao P, Zhang LL (2021) Oxidation resistance of nickel-based superalloy Inconel 600 in air at different temperatures. Rare Met 40:3235–3240. https://doi.org/10.1007/s12598-018-1148-1
Pratheesh Kumar S, Elangovan S, Mohanraj R, Ramakrishna JR (2021) A review on properties of Inconel 625 and Inconel 718 fabricated using direct energy deposition. Mater Today Proc 46:7892–7906. https://doi.org/10.1016/j.matpr.2021.02.566
Hu Y, Lin X, Li Y, Zhang S, Zhang Q, Chen W (2021) Influence of heat treatments on the microstructure and mechanical properties of Inconel 625 fabricated by directed energy deposition. Mater Sci Eng A 817:. https://doi.org/10.1016/j.msea.2021.141309
Bushlya V, Zhou J, Ståhl JE (2012) Effect of cutting conditions on machinability of superalloy Inconel 718 during high speed turning with coated and uncoated PCBN tools. Procedia CIRP 3:370–375. https://doi.org/10.1016/j.procir.2012.07.064
Ulutan D, Arisoy YM, Özel T, Mears L (2014) Empirical modeling of residual stress profile in machining nickel-based superalloys using the sinusoidal decay function. Procedia CIRP 13:365–370. https://doi.org/10.1016/j.procir.2014.04.062
Zhou J, Bushlya V, Avdovic P, Ståhl JE (2012) Study of surface quality in high speed turning of Inconel 718 with uncoated and coated CBN tools. Int J Adv Manuf Technol 58:141–151. https://doi.org/10.1007/s00170-011-3374-7
Umbrello D (2013) Investigation of surface integrity in dry machining of Inconel 718. Int J Adv Manuf Technol 69:2183–2190. https://doi.org/10.1007/s00170-013-5198-0
Lee SM, Chow HM, Yan BH (2007) Friction drilling of IN-713LC cast superalloy. Mater Manuf Process 22:893–897. https://doi.org/10.1080/10426910701451697
Zou B, Chen M, Huang C, An Q (2009) Study on surface damages caused by turning NiCr20TiAl nickel-based alloy. J Mater Process Technol 209:5802–5809. https://doi.org/10.1016/j.jmatprotec.2009.06.017
Ezilarasan C, Senthil Kumar VS, Velayudham A (2013) An experimental analysis and measurement of process performances in machining of nimonic C-263 super alloy. Measurement 46:185–199. https://doi.org/10.1016/j.measurement.2012.06.006
Ezilarasan C, Senthil Kumar VS, Velayudham A (2013) Effect of machining parameters on surface integrity in machining Nimonic C-263 super alloy using whisker-reinforced ceramic insert. J Mater Eng Perform 22:1619–1628. https://doi.org/10.1007/s11665-012-0439-1
Ezilarasan C, Senthil Kumar VS, Velayudham A (2014) Theoretical predictions and experimental validations on machining the Nimonic C-263 super alloy. Simul Model Pract Theory 40:192–207. https://doi.org/10.1016/j.simpat.2013.09.008
Yamaguchi Y, Abe M, Tajima R, Terada Y (2020) Microstructure evolution during isothermal aging for wrought nickel-based superalloy udimet 520+1. Mater Trans 61:1689–1697. https://doi.org/10.2320/matertrans.MT-M2020115
Nematzadeh F, Akbarpour MR, Kokabi AH, Sadrnezhaad SK (2009) Structural changes of radial forging die surface during service under thermo-mechanical fatigue. Mater Sci Eng A 527:98–102. https://doi.org/10.1016/j.msea.2009.07.068
Joshi S V., Paul Vizhian S, Sridhar BR, Jayaram K (2008) Parametric study of machining effect on residual stress and surface roughness of nickel base super alloy UDIMET 720. Adv Mater Res 47–50 PART:13–16. https://doi.org/10.4028/www.scientific.net/amr.47-50.13
Cui C, Gu Y, Harada H, Sato A (2005) Microstructure and yield strength of UDIMET 720LI alloyed with Co-16.9 Wt Pct Ti. Metall Mater Trans A Phys Metall Mater Sci 36:2921–2927. https://doi.org/10.1007/s11661-005-0065-8
Hood R, Soo SL, Aspinwall DK, Andrews P (2011) Twist drilling of haynes 282 superalloy. Procedia Eng 19:150–155. https://doi.org/10.1016/j.proeng.2011.11.094
Hood R, Soo SL, Aspinwall DK, Andrews P, Sage C (2012) Radius end milling of Haynes 282 nickel based superalloy. 226:1745–1753. https://doi.org/10.1177/0954405412455886
Ghazi AR, Khan HI, Farooq M, Jahangir S, Anwar MT (2023) Effect of temperature and medium environment on corrosion fatigue behavior of Inconel 625. Mater Corros. https://doi.org/10.1002/maco.202313748
Thébaud L, Villechaise P, Cormier J, Crozet C, Devaux A, Bechet D, Franchet JM (2015) Relationships between microstructural parameters and time-dependent mechanical properties of a new nickel-based superalloy AD730™. Metals (Basel) 5:2236–2251. https://doi.org/10.3390/met5042236
Shah P, Khanna N, Chetan (2020) Comprehensive machining analysis to establish cryogenic LN2 and LCO2 as sustainable cooling and lubrication techniques. Tribol Int 148:106314. https://doi.org/10.1016/j.triboint.2020.106314
Kwong J, Axinte DA, Withers PJ, Hardy MC (2009) Minor cutting edge-workpiece interactions in drilling of an advanced nickel-based superalloy. Int J Mach Tools Manuf 49:645–658. https://doi.org/10.1016/j.ijmachtools.2009.01.012
Marinescu I, Axinte DA (2008) A critical analysis of effectiveness of acoustic emission signals to detect tool and workpiece malfunctions in milling operations. Int J Mach Tools Manuf 48:1148–1160. https://doi.org/10.1016/j.ijmachtools.2008.01.011
M’Saoubi R, Axinte D, Herbert C, Hardy M, Salmon P (2014) Surface integrity of nickel-based alloys subjected to severe plastic deformation by abusive drilling. CIRP Ann - Manuf Technol 63:61–64. https://doi.org/10.1016/j.cirp.2014.03.067
Ezugwu EO, Wang ZM, Okeke CI (1999) Tool life and surface integrity when machining inconel 718 with pvd- and cvd-coated tools. Tribol Trans 42:353–360. https://doi.org/10.1080/10402009908982228
Tan L, Yao C, Li X, Fan Y, Cui M (2022) Effects of machining parameters on surface integrity when turning Inconel 718. J Mater Eng Perform 31:4176–4186. https://doi.org/10.1007/s11665-021-06523-4
Sharman ARC, Hughes JI, Ridgway K (2004) Workpiece Surface integrity and tool life issues when turning Inconel 718? nickel based superalloy. Mach Sci Technol 8:399–414. https://doi.org/10.1081/lmst-200039865
Arunachalam R, Mannan M, Spowage A (2004) Residual stress and surface roughness when facing age hardened Inconel 718 with CBN and ceramic cutting tools. Int J Mach Tools Manuf 44:879–887. https://doi.org/10.1016/j.ijmachtools.2004.02.016
Sadat AB, Reddy MY, Wang BP (1991) Plastic deformation analysis in machining of Inconel-718 nickel-base superalloy using both experimental and numerical methods. Int J Mech Sci 33:829–842. https://doi.org/10.1016/0020-7403(91)90005-N
Xu D, Liao Z, Axinte D, Hardy M (2020) A novel method to continuously map the surface integrity and cutting mechanism transition in various cutting conditions. Int J Mach Tools Manuf 151:. https://doi.org/10.1016/j.ijmachtools.2020.103529
Zhou JM, Bushlya V, Peng RL, Johansson S (2011) Effects of tool wear on subsurface deformation of nickel-based superalloy. Procedia Eng 19:407–413. https://doi.org/10.1016/j.proeng.2011.11.133
Imran M, Mativenga PT, Gholinia A, Withers PJ (2015) Assessment of surface integrity of Ni superalloy after electrical-discharge, laser and mechanical micro-drilling processes. Int J Adv Manuf Technol 79:1303–1311. https://doi.org/10.1007/s00170-015-6909-5
Bushlya V, Zhou JM, Lenrick F, Avdovic P, Stahl JE (2011) Characterization of white layer generated when turning aged Inconel 718. Procedia Eng 19:60–66. https://doi.org/10.1016/j.proeng.2011.11.080
M’Saoubi R, Larsson T, Outeiro J, Guo Y, Suslov S (2012) Surface integrity analysis of machined Inconel 718 over multiple length scales. CIRP Ann - Manuf Technol 61:99–102. https://doi.org/10.1016/j.cirp.2012.03.058
Ranganath S, Guo C, Hegde P (2009) A finite element modeling approach to predicting white layer formation in nickel superalloys. CIRP Ann - Manuf Technol 58:77–80. https://doi.org/10.1016/j.cirp.2009.03.109
Herbert C, Axinte DA, Hardy M, Withers P (2014) Influence of surface anomalies following hole making operations on the fatigue performance for a nickel-based superalloy. J Manuf Sci Eng 136:1–9. https://doi.org/10.1115/1.4027619
Jin D, Liu Z (2012) Effect of cutting speed on surface integrity and chip morphology in high-speed machining of PM nickel-based superalloy FGH95. Int J Adv Manuf Technol 60:893–899. https://doi.org/10.1007/s00170-011-3679-6
Umbrello D, Filice L (2009) Improving surface integrity in orthogonal machining of hardened AISI 52100 steel by modeling white and dark layers formation. CIRP Ann - Manuf Technol 58:73–76. https://doi.org/10.1016/j.cirp.2009.03.106
Österle W, Li PX (1997) Mechanical and thermal response of a nickel-base superalloy upon grinding with high removal rates. Mater Sci Eng A 238:357–366. https://doi.org/10.1016/S0921-5093(97)00457-7
Sauvage X, Le Breton JM, Guillet A, Meyer A (2003) Phase transformations in surface layers of machined steels investigated by X-ray diffraction and Mössbauer spectrometry. Mater Sci Eng A 362:181–186. https://doi.org/10.1016/S0921-5093(03)00531-8
Soo SL, Hood R, Aspinwall DK, Voice WE, Sage C (2011) Machinability and surface integrity of RR1000 nickel based superalloy. CIRP Ann - Manuf Technol 60:89–92. https://doi.org/10.1016/j.cirp.2011.03.094
Augspurger T, Meurer M, Liu H, Mattfeld P, Bergs T (2020) Experimental study of the connection between process parameters, thermo-mechanical loads and surface integrity in machining Inconel 718. Procedia CIRP 87:59–64. https://doi.org/10.1016/j.procir.2020.02.081
Akhavan Niaki F, Mears L (2017) A comprehensive study on the effects of tool wear on surface roughness, dimensional integrity and residual stress in turning IN718 hard-to-machine alloy. J Manuf Process 30:268–280. https://doi.org/10.1016/j.jmapro.2017.09.016
Che-Haron CH, Jawaid A (2005) The effect of machining on surface integrity of titanium alloy Ti-6% Al-4% v. J Mater Process Technol 166:188–192. https://doi.org/10.1016/j.jmatprotec.2004.08.012
Akhavan Farid A, Sharif S, Namazi H (2009) Effect of machining parameters and cutting edge geometry on surface integrity when drilling and hole making in Inconel 718. SAE Int J Mater Manuf 2:564–569. https://doi.org/10.4271/2009-01-1412
Axinte DA, Andrews P, Li W, Gindy N, Withers PJ (2006) Turning of advanced Ni based alloys obtained via powder metallurgy route. CIRP Ann - Manuf Technol 55:117–120. https://doi.org/10.1016/S0007-8506(07)60379-5
Herbert CRJ, Kwong J, Kong MC, Axinte DA (2012) An evaluation of the evolution of workpiece surface integrity in hole making operations for a nickel-based superalloy. J Mater Process Technol 212:1723–1730. https://doi.org/10.1016/j.jmatprotec.2012.03.014
Thakur A, Mohanty A, Gangopadhyay S (2014) Comparative study of surface integrity aspects of Incoloy 825 during machining with uncoated and CVD multilayer coated inserts. Appl Surf Sci 320:829–837. https://doi.org/10.1016/j.apsusc.2014.09.129
Imran M, Mativenga PT, Gholinia A, Withers PJ (2011) Evaluation of surface integrity in micro drilling process for nickel-based superalloy. 465–476. https://doi.org/10.1007/s00170-010-3062-z
Jin D, Liu Z (2013) Damage of the machined surface and subsurface in orthogonal milling of FGH95 superalloy. Int J Adv Manuf Technol 68:1573–1581. https://doi.org/10.1007/s00170-013-4944-7
Du J, Liu Z, Lv S (2014) Deformation-phase transformation coupling mechanism of white layer formation in high speed machining of FGH95 Ni-based superalloy. Appl Surf Sci 292:197–203. https://doi.org/10.1016/j.apsusc.2013.11.111
Herbert C, Axinte D, Hardy M, Brown PD (2012) Investigation into the characteristics of white layers produced in a nickel-based superalloy from drilling operations. Mach Sci Technol 16:40–52. https://doi.org/10.1080/10910344.2012.648520
Fan Y, Hao Z, Zheng M, Sun FL, Yang SC (2013) Study of surface quality in machining nickel-based alloy Inconel 718. Int J Adv Manuf Technol 69:2659–2667. https://doi.org/10.1007/s00170-013-5225-1
Molaiekiya F, Aliakbari Khoei A, Aramesh M, Veldhuis SC (2021) Machined surface integrity of inconel 718 in high-speed dry milling using SiAlON ceramic tools. Int J Adv Manuf Technol 112:1941–1950. https://doi.org/10.1007/s00170-020-06471-8
Muhammad A, Kumar Gupta M, Mikołajczyk T, Pimenov DY, Giasin K (2021) Effect of tool coating and cutting parameters on surface roughness and burr formation during micromilling of Inconel 718. Metals (Basel) 11:167. https://doi.org/10.3390/met11010167
Ezilarasan C, Senthil Kumar VS, Velayudham A, Palanikumar K (2011) Modeling and analysis of surface roughness on machining of Nimonic C-263 alloy by PVD coated carbide insert. Trans Nonferrous Met Soc China 21:1986–1994. https://doi.org/10.1016/S1003-6326(11)60961-8
Klocke F, Vogtel P, Gierlings S, Lung D, Veselovac D (2013) Broaching of Inconel 718 with cemented carbide. 593–600. https://doi.org/10.1007/s11740-013-0483-1
Veldhuis SC, Dosbaeva GK, Elfizy A, Fox-Rabinovich GS, Wagg T (2010) Investigations of white layer formation during machining of powder metallurgical Ni-Based ME 16 superalloy. 19:1031–1036. https://doi.org/10.1007/s11665-009-9567-7
Herbert CRJ, Axinte DA, Hardy MC, Brown PD (2011) Investigation into the characteristics of white layers produced in a nickel-based superalloy from drilling operations. Procedia Eng 19:138–143. https://doi.org/10.1016/j.proeng.2011.11.092
Devillez A, Coz G Le, Dominiak S, Dudzinski D (2011) Journal of materials processing technology dry machining of Inconel 718, workpiece surface integrity. 211:1590–1598. https://doi.org/10.1016/j.jmatprotec.2011.04.011
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
Aramcharoen A, Chuan SK (2014) An experimental investigation on cryogenic milling of Inconel 718 and its sustainability assessment. Procedia CIRP 14:529–534. https://doi.org/10.1016/j.procir.2014.03.076
Yy à (2008) Nalbant M. A review of cryogenic cooling in machining processes 48:947–964. https://doi.org/10.1016/j.ijmachtools.2008.01.008
Ding R, Knaggs C, Li H, Li YG, Bowen P (2020) Characterization of plastic deformation induced by machining in a Ni-based superalloy. Mater Sci Eng A 778:139104. https://doi.org/10.1016/j.msea.2020.139104
Kumar S, Kumar A (2023) Optimization of machining ability of nickel alloy 685. Int Res J Mod Eng Technol Sci 635–642. https://doi.org/10.56726/irjmets33479
Tian P, He L, Zhou T, Du F, Zou Z, Zhou X (2023) Experimental characterization of the performance of MQL-assisted turning of solution heat-treated and aged Inconel 718 alloy. Int J Adv Manuf Technol 125:3839–3851. https://doi.org/10.1007/s00170-023-10890-8
Danish M, Gupta MK, Rubaiee S, Ahmed A (2021) Influence of hybrid Cryo-MQL lubri-cooling strategy on the machining and tribological characteristics of Inconel 718. Tribol Int 163:107178. https://doi.org/10.1016/j.triboint.2021.107178
Imran M, Mativenga PT, Gholinia A, Withers PJ (2014) Comparison of tool wear mechanisms and surface integrity for dry and wet micro-drilling of nickel-base superalloys. Int J Mach Tools Manuf 76:49–60. https://doi.org/10.1016/j.ijmachtools.2013.10.002
Sugihara T, Enomoto T (2015) High speed machining of Inconel 718 focusing on tool surface topography of CBN Tool. 1:675–682. https://doi.org/10.1016/j.promfg.2015.09.010
Liang X, Liu Z (2017) Experimental investigations on effects of tool flank wear on surface integrity during orthogonal dry cutting of Ti-6Al-4V. Int J Adv Manuf Technol 93:1617–1626. https://doi.org/10.1007/s00170-017-0654-x
Pawade RS, Joshi SS, Brahmankar PK (2008) Effect of machining parameters and cutting edge geometry on surface integrity of high-speed turned Inconel 718. Int J Mach Tools Manuf 48:15–28. https://doi.org/10.1016/j.ijmachtools.2007.08.004
Sharman ARC, Hughes JI, Ridgway K (2006) An analysis of the residual stresses generated in Inconel 718 TM when turning. 173:359–367. https://doi.org/10.1016/j.jmatprotec.2005.12.007
Khanna N, Shah P, Chetan (2020) Comparative analysis of dry, flood, MQL and cryogenic CO2 techniques during the machining of 15–5-PH SS alloy. Tribol Int 146:. https://doi.org/10.1016/j.triboint.2020.106196
Rao CM, Sachin B, Rao SS, Herbert MA (2021) Minimum quantity lubrication through the micro-hole textured PCD and PCBN inserts in the machining of the Ti–6Al–4V alloy. Tribol Int 153:. https://doi.org/10.1016/j.triboint.2020.106619
Thakur DG, Ramamoorthy B, Vijayaraghavan L (2012) Effect of cutting parameters on the degree of work hardening and tool life during high-speed machining of Inconel 718. Int J Adv Manuf Technol 59:483–489. https://doi.org/10.1007/s00170-011-3529-6
Ramoni M, Shanmugam R, Ross NS, Gupta MK (2021) An experimental investigation of hybrid manufactured SLM based Al-Si10-Mg alloy under mist cooling conditions. J Manuf Process 70:225–235. https://doi.org/10.1016/j.jmapro.2021.08.045
Bhirud NL, Gawande RR (2017) Measurement and prediction of cutting temperatures during dry milling : review and discussions. J Brazilian Soc Mech Sci Eng 39:5135–5158. https://doi.org/10.1007/s40430-017-0869-7
Liang X, Liu Z, Wang B (2019) State-of-the-art of surface integrity induced by tool wear effects in machining process of titanium and nickel alloys: a review. Meas J Int Meas Confed 132:150–181. https://doi.org/10.1016/j.measurement.2018.09.045
Hood R, Soo SL, Aspinwall DK, Mantle AL (2018) Tool life and workpiece surface integrity when turning an RR1000 nickel-based superalloy. Int J Adv Manuf Technol 98:2461–2468. https://doi.org/10.1007/s00170-018-2371-5
Saleem MQ, Mumtaz S (2020) Face milling of Inconel 625 via wiper inserts: evaluation of tool life and workpiece surface integrity. J Manuf Process 56:322–336. https://doi.org/10.1016/j.jmapro.2020.04.011
Makhesana MA, Patel KM, Krolczyk GM (2023) Influence of MoS2 and graphite-reinforced nanofluid-MQL on surface roughness, tool wear, cutting temperature and microhardness in machining of Inconel 625. CIRP J Manuf Sci Technol 41:225–238. https://doi.org/10.1016/j.cirpj.2022.12.015
Sarıkaya M, Gupta MK, Tomaz I, Pimenov DY (2021) A state-of-the-art review on tool wear and surface integrity characteristics in machining of superalloys. CIRP J Manuf Sci Technol 35:624–658. https://doi.org/10.1016/j.cirpj.2021.08.005
Jafarian F, Amirabadi H, Sadri J, Banooie HR (2014) Simultaneous optimizing residual stress and surface roughness in turning of Inconel718 superalloy. Mater Manuf Process 29:337–343. https://doi.org/10.1080/10426914.2013.864413
Özel T, Ulutan D (2012) Prediction of machining induced residual stresses in turning of titanium and nickel based alloys with experiments and finite element simulations. CIRP Ann 61:547–550. https://doi.org/10.1016/j.cirp.2012.03.100
Xin H, Shi Y, Ning L, Zhao T (2016) Residual stress and affected layer in disc milling of titanium alloy. Mater Manuf Process 31:1645–1653. https://doi.org/10.1080/10426914.2015.1090583
Zhou J, Bushlya V, Lin R, Chen Z, Johansson S (2014) Analysis of subsurface microstructure and residual stresses in machined Inconel 718 with PCBN and Al 2 O 3 -SiC w tools. 13:150–155. https://doi.org/10.1016/j.procir.2014.04.026
Axinte D, Dewes R (2002) Surface integrity of hot work tool steel after high speed milling-experimental data and empirical models. J Mater Process Technol 127:325–335. https://doi.org/10.1016/S0924-0136(02)00282-0
Valentini E, Bertelli L, Benincasa A, Gulisano S (2020) Recent advancements in the hole-drilling strain-gage method for determining residual stresses. In: New challenges in residual stress measurements and evaluation. IntechOpen https://doi.org/10.5772/intechopen.90392
Guo J, Fu H, Pan B, KANG R, (2021) Recent progress of residual stress measurement methods: a review. Chinese J Aeronaut 34:54–78. https://doi.org/10.1016/j.cja.2019.10.010
Lodh A, Thool K, Samajdar I (2022) X-ray diffraction for the determination of residual stress of crystalline material: an overview. Trans Indian Inst Met 75:983–995. https://doi.org/10.1007/s12666-022-02540-6
Jacobson M, Dahlman P, Gunnberg F (2002) Cutting speed influence on surface integrity of hard turned bainite steel. J Mater Process Technol 128:318–323. https://doi.org/10.1016/S0924-0136(02)00472-7
Rao B, Shin YC (2001) Analysis on high-speed face-milling of 7075–T6 aluminum using carbide and diamond cutters. Int J Mach Tools Manuf 41:1763–1781. https://doi.org/10.1016/S0890-6955(01)00033-5
Sharman ARC, Hughes JI, Ridgway K (2015) The effect of tool nose radius on surface integrity and residual stresses when turning Inconel 718™. J Mater Process Technol 216:123–132. https://doi.org/10.1016/j.jmatprotec.2014.09.002
Holmberg J, Wretland A, Berglund J, Beno T (2020) A detailed investigation of residual stresses after milling Inconel 718 using typical production parameters for assessment of affected depth. Mater Today Commun 24:100958. https://doi.org/10.1016/j.mtcomm.2020.100958
Javidi A, Rieger U, Eichlseder W (2008) Int J Fatigue The effect of Mach Surface Integr Fatigue Life 30:2050–2055. https://doi.org/10.1016/j.ijfatigue.2008.01.005
Dixit APAR, Uddin SCMS, Dong Y (2017) Fatigue life of machined componentshttps://doi.org/10.1007/s40436-016-0168-z
Sun J, Guo YB (2009) Journal of Materials Processing Technology A comprehensive experimental study on surface integrity by end milling Ti – 6Al – 4V. 209:4036–4042. https://doi.org/10.1016/j.jmatprotec.2008.09.022
Wusatowska-Sarnek AM, Dubiel B, Czyrska-Filemonowicz A, Bhowal PR, Ben Salah N (2011) Microstructural characterization of the white etching layer in nickel-based superalloy. Metall Mater Trans A 42:3813–3825. https://doi.org/10.1007/s11661-011-0779-8
Dutilh V, Dessein G, Alexis J, Perrin G (2010) Links between machining parameters and surface integrity in drilling Ni-superalloy. Adv Mater Res 112:171–178. https://doi.org/10.4028/www.scientific.net/AMR.112.171
Vincent Dutilh, Andreï Popa, Gilles Dessein, Joël Alexis GP (2010) Impact of disturbed drilling conditions on the surface integrity of a nickel-base superalloy. In: CIRP ICME ’10 - 7th CIRP International Conference on INTELLIGENT COMPUTATION IN MANUFACTURING ENGINEERING. hal-00944562, Capri, Italy. https://hal.science/hal-00944562
Sharman ARC, Hughes JI, Ridgway K (2006) Machining science and technology : an international workpiece surface integrity and tool life issues when turning Inconel 718 TM nickel based superalloy workpiece surface integrity and tool life issues. 37–41. https://doi.org/10.1081/LMST-200039865
Xu Y, Gong Y, Wang Z, Wen X, Yin G, Zhang H, Qi Y (2021) Experimental study of Ni - based single - crystal superalloy : microstructure evolution and work hardening of ground subsurface. Arch Civ Mech Eng 21:1–11. https://doi.org/10.1007/s43452-021-00203-9
Saleem MQ, Mehmood A (2022) Eco-friendly precision turning of superalloy Inconel 718 using MQL based vegetable oils: tool wear and surface integrity evaluation. J Manuf Process 73:112–127. https://doi.org/10.1016/j.jmapro.2021.10.059
Hill C (2002) Residual stresses VI , ECRS6. 407:173–178. https://doi.org/10.4028/www.scientific.net/MSF.404-407.173
Cai X, Qin S, Li J, An Q, Chen M (2014) Experimental investigation on surface integrity of end milling nickel-based alloy— Inconel 718. Mach Sci Technol 18:31–46. https://doi.org/10.1080/10910344.2014.863627
Pusavec F, Hamdi H, Kopac J, Jawahir IS (2011) Surface integrity in cryogenic machining of nickel based alloy - Inconel 718. J Mater Process Technol 211:773–783. https://doi.org/10.1016/j.jmatprotec.2010.12.013
Ross NS, Srinivasan N, Amutha P, Gupta MK (2022) Thermo-physical, tribological and machining characteristics of Hastelloy C276 under sustainable cooling/lubrication conditions. J Manuf Process 80:397–413. https://doi.org/10.1016/j.jmapro.2022.06.018
Podder B, Paul S (2012) Improvement of machinability in end milling of Nimonic C-263 by application of high pressure coolant. Int J Mach Mach Mater 11:418. https://doi.org/10.1504/IJMMM.2012.047837
Rahim EA, Sasahara H Machining science and technology : an analysis of surface integrity when drilling Inconel 718 using palm oil and synthetic ester under mql condition. 37–41. https://doi.org/10.1080/10910344.2011.557967
Sharman ARC, Hughes JI, Ridgway K (2008) Surface integrity and tool life when turning Inconel 718 using ultra-high pressure and flood coolant systems. 222:653–664. https://doi.org/10.1243/09544054JEM936
Amigo FJ, Urbikain G, Pereira O (2020) Combination of high feed turning with cryogenic cooling on Haynes 263 and Inconel 718 superalloys. J Manuf Process 58:208–222. https://doi.org/10.1016/j.jmapro.2020.08.029
Coelho RT, Silva LR, Braghini A, Bezerra AA (2004) Some effects of cutting edge preparation and geometric modifications when turning Inconel 718 TM at high cutting speeds. 148:147–153. https://doi.org/10.1016/j.jmatprotec.2004.02.001
Madariaga A, Esnaola JA, Fernandez E (2014) Analysis of residual stress and work-hardened profiles on Inconel 718 when face turning with large-nose radius tools. 1587–1598. https://doi.org/10.1007/s00170-013-5585-6
Thakur A, Dewangan S, Patnaik Y, Gangopadhyay S (2014) Prediction of work hardening during machining Inconel 825 using fuzzy logic method. Procedia Mater Sci 5:2046–2053. https://doi.org/10.1016/j.mspro.2014.07.538
Outeiro JC, Pina JC, Saoubi RM, Pusavec F, Jawahir IS (2008) CIRP Annals - Manufacturing technology analysis of residual stresses induced by dry turning of difficult-to-machine materials. 57:77–80https://doi.org/10.1016/j.cirp.2008.03.076
Li W, Withers PJ, Axinte D, Preuss M (2009) Journal of materials processing technology residual stresses in face finish turning of high strength nickel-based superalloy. 209:4896–4902https://doi.org/10.1016/j.jmatprotec.2009.01.012
Funding
This work was supported by the Key Research & Development Program of Shandong Province (Grant No. 2021SFGC0902) and Taishan Scholar Project of Shandong Province (No. ts201712002).
Author information
Authors and Affiliations
Contributions
All the authors contributed to the study. GM has made a substantial effort to design, research, and writing of this article. BL helped to draft the manuscript, and SZ finalized the content of the manuscript including revisions and edits. All authors read and approved the final manuscript.
Corresponding author
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 (e.g. a society or other partner) 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.
About this article
Cite this article
Mustafa, G., Li, B. & Zhang, S. Cutting condition effects on microstructure and mechanical characteristics of Ni-based superalloys—a review. Int J Adv Manuf Technol 130, 3179–3209 (2024). https://doi.org/10.1007/s00170-023-12910-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-023-12910-z