Cutting Parameters for Roughing Turning of Alloy 625 Clad Using Ceramic Inserts

Abstract

Nickel alloy 625 is widely used in submarine equipment for the oil and gas industry, which operate in an extremely adverse environment. In order to reduce the costs of these components, weld overlay cladding is employed. The surface generated by this process presents some irregularities that represent an additional difficulty to the machining process. The present work investigates the use of whiskers-reinforced ceramic tools and SiAlON in turning of alloy 625 clad on AISI 4130 steel by an automatic tungsten inert gas (TIG) cladding system. The results indicate the feasibility of the industrial application of the SiAlON inserts in rough turning of the alloy 625 clad, as well as the impossibility of using whiskers-reinforced ceramic tools (Al2O3 + SiCw) in the same conditions. The highest flank and notch wear of the SiAlON inserts were observed for the lowest cutting speed (140 m/min), which induced the formation of burrs in the workpiece at the depth of cut. Adhesion occurred more intensively at this condition. The least flank and notch wear were achieved by using cutting speed of 160 m/min and feed-rate of 0.25 mm/rev. Prolonged turning with worn tools resulted in microstructural alterations of the workpiece material and surface damages.

Parametric Optimization and Modeling for Flank Wear of Tisin-Tialn Nanolaminate Cutting Insert

“…It was seen that as the cutting speed and depth of cut increases, flank wear increases. This concurs with the studies of Gabriel & Milton [37], Dureja et al [38], Lopez-Luiz et al [39], Das et al [40], Singh & Kumar [41], Rajesh Kumar Bhushan [42], Varaprasad et al [43], Suresh et al [44], and Tian-Syung Lan [45], the increment in cutting speed remarkably increases temperature at the interaction of tool tip and work piece and leads to more flank wear.…”

Ceramic Cutting Materials and Tools Suitable for Machining High-Temperature Nickel-Based Alloys: A Review

“…Much research has been conducted to determine the effectiveness of sialon application, compared to other ceramics [159][160][161]. For instance, Krebs et al [162] investigated the use of ceramic tools whisker-reinforced SiAlON when turning on the clad alloy steel AISI 625 4130 via an automatic system for cladding a tungsten inert gas (TIG). It has been experimentally established that the use of cutting inserts from SiAlON for rough turning of clad alloy 625 is very effective.…”

“…It has been experimentally established that the use of cutting inserts from SiAlON for rough turning of clad alloy 625 is very effective. The use of corundum ceramics (Al 2 O 3 ) reinforced with whiskers (SiC w ) under the same conditions is ineffective [162]. The application of SiAlON inserts contributes to an increase in the removal rate of the work material when compared with the possibilities of using a carbide tool, including those with wear-resistant coatings.…”

Machinability of Nickel-Based Superalloys Using Ceramic Tools

“…The use of cubic boron nitride (CBN) as a cutting tool in the processing of heat-resistant nickel alloys is poorly understood. Basically, CBN used in the treatment of increased material hardness (45)(46)(47)(48)(49)(50)(51)(52)(53)(54)(55)(56)(57)(58)(59)(60), such as hardened steel [33] or ductile iron [34,35].…”

“…Much research has been done to determine the effectiveness of sialons application compared to other ceramics. For instance, Krebs et al [57] investigated the use of whiskers-reinforced ceramic tools and SiAlON in turning of alloy 625 clad on AISI 4130 steel by an automatic tungsten inert gas (TIG) cladding system. The results indicate the feasibility of the industrial application of the SiAlON inserts in rough turning of the alloy 625 clad, as well as the impossibility of using whiskers-reinforced ceramic tools (Al2O3+SiCw) in the same conditions.…”