An Evaluation on Machinability Characteristics of Titanium and Nickel Based Superalloys Used in Aerospace Industry

Abstract

Superalloys are a group of materials that are commonly used in aerospace applications and are also called high temperature materials, as they have superior wear and corrosion resistance. Ni-based superalloys are used more often than Ti alloys in the aerospace industry as they have mechanical and physical properties such as superior temperature resistance and toughness, high corrosion resistance, excellent fatigue and creep resistance. Ti alloys, on the other hand, have the highest strength / weight ratio among metals, increasing their preference in these industries continuously. Casting, forging, powder metallurgy and machining methods are used in the process of shaping machine parts used in the aviation industry from superalloys. However, many components are mostly manufactured using machining methods due to the part geometry, desired size and surface quality requirements. In this context, in the production of parts from Ti alloys and Ni-based superalloys, which are difficult to process, the correct selection or optimization of processing parameters is very important in terms of minimization of processing costs and therefore sustainable manufacturing. In this study, factors such as cutting tool quality and cooling/lubrication technology were evaluated for criteria such as tool life, surface integrity and cutting forces, which have an important place in the machinability of titanium and nickel-based superalloys.

Diametral deviation and tool wear analysis in EDM of Fe-based shape memory alloy: An experimental study with microstructural analysis and advanced optimization

“…28 When the pulse on time and peak current are increased, the surface of the work sample develops additional microcracks, craters, and debris, according to the Yurtkuran. 21 As seen in Figure 7, the quantity of debris in the flow has grown as the pulse length and peak current have increased. The faster the pulse, the more likely a spark may develop, resulting in a rise in temperature.…”

“…EDM is a non-traditional machining technique that can create intricate shapes, microscopic holes, and cavities. [18][19][20][21][22] Electric spark cut machining is a thermal technique, utilizing selected pulsed releases that may be temporarily and spatially controlled to treat electrical conductively material regardless of their thermo-physical, chemical and mechanical characteristics. 22 The EDM method was discovered in the 1940s.…”

“…EDM is a non-traditional machining technique that can create intricate shapes, microscopic holes, and cavities. 18–22…”

“…19,20 Shape memory alloys fall under the group of difficult-to-cut advanced materials, hence EDM is quite successful in machining these alloys. 21 In context with the aforementioned research-based studies in the domain of electrical discharge machining of shape memory alloys, the several experimental studies neglect to examine the TWR and DD of the electrode and work sample while cutting Fe-based SMA in EDM operations. Several researchers have avoided looking at process variables like peak current and gap voltage and how they affect the machining of Fe-based SMA.…”

A novel approach of tool condition monitoring in sustainable machining of Ni alloy with transfer learning models

“…Metal cutting is a significant production operation that consumes a huge amount of energy during the machining of varied materials (Demirsöz & Boy, 2022). Because of their greater level of mechanical properties, Ni-based alloys present machinability issues during the cutting process (Yurtkuran, 2021). The concern about tool failure, tool life, and machinability has sparked a great deal of scientific interest, the majority of which has been dedicated towards conventional machining processes (Waydande et al, 2016).…”