Key improvements in the machining of difficult-to-cut aerospace superalloys

• Published in: International journal of machine tools & manufacture Vol. 45; no. 12; pp. 1353 - 1367
• Main Author: Ezugwu, E.O.
• Format: Journal Article
• Language: English
• Published: Oxford Elsevier Ltd 01.10.2005; Elsevier
• Subjects: Applied sciences; Exact sciences and technology; High temperature alloys; Hot machining; Mechanical engineering. Machine design; Metals. Metallurgy; Rotary cutting tools; Hot machining; Rotary cutting tools; High temperature alloys; Structure integrity; Machining; Processing time; High temperature; Modeling; Titanium base alloys; Aerospace industry; Cutting tool materials; Research and development; Superalloy; Aerospace; Dimensional control; Thermal conductivity; Wear resistance; Manufacturing cost; Thermal conduction; Thermal characteristic; Productivity; Nickel base alloys; Chemical resistance; Machinability; Hardness; Operating conditions; Roundness; Material engineering
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2005.02.003

Significant advances have been made in understanding the behaviour of engineering materials when machining at higher cutting conditions from practical and theoretical standpoints. This approach has enabled the aerospace industry to cope with constant introduction of new materials that allow the engine temperature to increase at a rate of 10 °C per annum since the 1950s. Improvements achieved from research and development activities in this area have particularly enhanced the machining of difficult-to-cut nickel base and titanium alloys that have traditionally exhibited low machinability due to their peculiar characteristics such as poor thermal conductivity, high strength at elevated temperature, resistance to wear and chemical degradation, etc. A good understanding of the cutting tool materials, cutting conditions, processing time and functionality of the machined component will lead to efficient and economic machining of nickel and titanium base superalloys. This paper presents an overview of major advances in machining techniques that have resulted to step increase in productivity, hence lower manufacturing cost, without adverse effect on the surface finish, surface integrity, circularity and hardness variation of the machined component.