Review on machining of additively manufactured nickel and titanium alloys

The machining of nickel and titanium-based superalloy components is very expensive and involves unusually high lead times compared with other engineering metals such as steels and aluminum. This has led to the development of most suitable additive manufacturing (AM) processes to fabricate these diff...

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Published inJournal of materials research and technology Vol. 15; pp. 3192 - 3221
Main Authors Khanna, Navneet, Zadafiya, Kishan, Patel, Tej, Kaynak, Yusuf, Rahman Rashid, Rizwan Abdul, Vafadar, Ana
Format Journal Article
LanguageEnglish
Published Elsevier B.V 01.11.2021
Elsevier
Subjects
Additive manufacturing
Machining
Nickel alloy
Surface integrity analysis
Titanium alloys
Tool wear analysis
Surface integrity analysis
Titanium alloys
Tool wear analysis
Additive manufacturing
Nickel alloy
Machining
Online AccessGet full text
ISSN2238-7854
DOI10.1016/j.jmrt.2021.09.088

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Abstract The machining of nickel and titanium-based superalloy components is very expensive and involves unusually high lead times compared with other engineering metals such as steels and aluminum. This has led to the development of most suitable additive manufacturing (AM) processes to fabricate these difficult-to-machine metals into near-net shape parts, thereby reducing the lead time and material waste, and significantly increasing productivity. Nonetheless, finish machining is still required on the AMed metal components to meet the dimensional and surface requirements of the application. Several research studies have investigated the machinability of AMed nickel and titanium alloy workpieces and have compared the results with the machining responses of wrought counterparts, which is detailed in this review. The categorization of the literature is based on the machining operations including turning, milling, drilling, and non-conventional machining, and the observations are discussed in accordance with various input parameters such as workpiece characteristics (hardness, microstructures) and anisotropy in mechanical properties due to build orientations during the AM process. Moreover, the influence of these parameters on cutting forces and temperatures, chip formation, and tool wear is analyzed and reported. From this review, it is found that the machinability of AMed nickel and titanium workpieces is quite different to the machining responses of their wrought counterparts. Further thorough experimentation is required to develop optimized machining parameters for AMed metal parts, while an exploration of different cutting tool geometries, coolant, and lubrication strategies for enhanced tool performance for machining AMed workpieces is essential. Finally, this study reviews the state of contemporary research, and offers suggestions for future research.
AbstractList The machining of nickel and titanium-based superalloy components is very expensive and involves unusually high lead times compared with other engineering metals such as steels and aluminum. This has led to the development of most suitable additive manufacturing (AM) processes to fabricate these difficult-to-machine metals into near-net shape parts, thereby reducing the lead time and material waste, and significantly increasing productivity. Nonetheless, finish machining is still required on the AMed metal components to meet the dimensional and surface requirements of the application. Several research studies have investigated the machinability of AMed nickel and titanium alloy workpieces and have compared the results with the machining responses of wrought counterparts, which is detailed in this review. The categorization of the literature is based on the machining operations including turning, milling, drilling, and non-conventional machining, and the observations are discussed in accordance with various input parameters such as workpiece characteristics (hardness, microstructures) and anisotropy in mechanical properties due to build orientations during the AM process. Moreover, the influence of these parameters on cutting forces and temperatures, chip formation, and tool wear is analyzed and reported. From this review, it is found that the machinability of AMed nickel and titanium workpieces is quite different to the machining responses of their wrought counterparts. Further thorough experimentation is required to develop optimized machining parameters for AMed metal parts, while an exploration of different cutting tool geometries, coolant, and lubrication strategies for enhanced tool performance for machining AMed workpieces is essential. Finally, this study reviews the state of contemporary research, and offers suggestions for future research.
Author Kaynak, Yusuf
Zadafiya, Kishan
Khanna, Navneet
Patel, Tej
Vafadar, Ana
Rahman Rashid, Rizwan Abdul
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  orcidid: 0000-0002-8094-4604
  surname: Khanna
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  email: navneetkhanna@iitram.ac.in
  organization: Advanced Manufacturing Laboratory, Institute of Infrastructure Technology Research and Management (IITRAM), Ahmedabad, 380026, India
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  givenname: Kishan
  surname: Zadafiya
  fullname: Zadafiya, Kishan
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  orcidid: 0000-0001-9779-9813
  surname: Patel
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  givenname: Yusuf
  surname: Kaynak
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  organization: Department of Mechanical Engineering, Marmara University, Goztepe Campus, 34722, Kadikoy, Istanbul, Turkey
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  orcidid: 0000-0002-2332-3465
  surname: Rahman Rashid
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  organization: School of Engineering, Swinburne University of Technology, Hawthorn, Victoria, 3122, Australia
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  givenname: Ana
  orcidid: 0000-0002-7697-6443
  surname: Vafadar
  fullname: Vafadar, Ana
  email: a.vafadarshamasbi@ecu.edu.au
  organization: School of Engineering, Edith Cowan University (ECU), Joondalup, 6027, Western Australia, Australia
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Keywords Surface integrity analysis
Titanium alloys
Tool wear analysis
Additive manufacturing
Nickel alloy
Machining
Language English
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Snippet The machining of nickel and titanium-based superalloy components is very expensive and involves unusually high lead times compared with other engineering...
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SubjectTerms Additive manufacturing
Machining
Nickel alloy
Surface integrity analysis
Titanium alloys
Tool wear analysis
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Title Review on machining of additively manufactured nickel and titanium alloys
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