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Inconel 625 sustainable milling surface integrity and the dependence on alloy processing route

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Abstract

The discovery of deepwater oil and gas sources has altered the scenario of world production of oil products, attracting even more attention to nickel superalloys. However, this class of materials can be used in several applications. Furthermore, nickel superalloys are highly dependent on their processing history, and the manner in which superalloys react to machining can directly affect the finished product. This work aims to evaluate the surface integrity of two different materials after cryogenic side-milling in conditions that stimulate severe plastic deformation (SPD) and high heat generation. The results show that the material response to machining depends strongly on the pre-processing route instead of most assumptions. While cryogenic cooling led to significant sub-surface hardness and microstructural changes in wrought Inconel 625 alloy, such changes were not observed for clad Inconel 625. Therefore, in order to achieve significant surface integrity changes, process parameters need to be selected and optimized accordingly. Also, the findings indicate that some new factors established significant affect/change surface integrity: (a) SPD through a high rβ/h ratio; (b) the specific pre-processing thermomechanical history of the workpiece material; and (c) and cryogenic cooling, by changing material properties, reducing temperature and altering cutting phenomena and chip formation.

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Acknowledgements

The authors gratefully acknowledge the technical assistance provided for the experimental work at the Institute for Sustainable Manufacturing (ISM) at the University of Kentucky. We would like to thank Laboratório de Fenômenos de Superfície – LFS, represented by Prof. Izabel Fernanda Machado, PhD.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Federal Technological University - Paraná, Campus Cornélio Procópio, Paraná, Brazil

    Rodrigo Henriques Lopes da Silva

  2. Department of Mechanical Engineering and Institute for Sustainable Manufacturing, University of Kentucky, Lexington, KY, USA

    Julius Schoop & I. S. Jawahir

  3. Department of Manufacturing and Materials Engineering, School of Mechanical Engineering, University of Campinas – UNICAMP, 200 Mendeleyev St., Barão Geraldo, 13083-860, Campinas, São Paulo, Brazil

    Amauri Hassui

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  1. Rodrigo Henriques Lopes da Silva
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The authors contributed to the study in all the phases of design of experiments, experimentation, writing, and analysis. Then, they read and approved the final manuscript.

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da Silva, R.H.L., Schoop, J., Hassui, A. et al. Inconel 625 sustainable milling surface integrity and the dependence on alloy processing route. Int J Adv Manuf Technol 130, 4493–4512 (2024). https://doi.org/10.1007/s00170-023-12938-1

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