Effects of Machining Parameters on Finishing Additively Manufactured Nickel-Based Alloy Inconel 625

Abstract

Metal additive manufacturing processes such as selective laser melting (SLM), laser powder bed fusion (L-PBF), electron beam melting (EBM) and laser metal deposition (LMD) can produce additively manufactured nearly fully dense parts with high geometrical complexity. These are often used as components in automotive, aerospace and medical device industries. Finish machining of these components is required to achieve the desired surface finish and dimensional tolerances. The investigations on additively manufactured alloys, as reported in the literature, indicate that a layer-wise scan strategy (orthogonal or layer-to-layer rotation) and process parameters have significant influences on the resultant microstructure which affects the final mechanical properties and fatigue life. The solidification microstructure depicts that growth directions of columnar grains and sizes of cellular grains that are affected by the layer-wise scan strategy. This paper presents experimental investigations on finish milling parameters on a nickel-based alloy manufactured with L-PBF using two distinct layer-wise scan strategies. The results reveal some effects of milling direction against the layer-wise build direction. The effects of cutting speed and feed rate on resultant cutting forces, chip formation, as well as surface finish at various cutting orientations in nickel-based alloy workpieces are reported.

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

“…It is known that the processed surface structure has a great influence on the equipment performance of parts such as fatigue life, wear and corrosion strength, and is closely connected to cutting conditions. It was also found that the fine structure of the alloy produced by the laminating process, unlike casting and forging, also affects the surface finish of the laminated geographic feature after the laminating process [95]. As shown in Figure 10, classics related to surface topography (defects and roughness), microstructure changes (deformation, particle miniaturization and texture) and mechanical characteristics (fine hardness and residual stress).…”

“…), Nimonic (75, 80A, 90, 263, PE 11, C-263, etc. ), Rene (41,95), Udimet (400, 500, 630, 700, etc. ), Pyromet 860, Astroloy, Waspaloy, Unitemp AF2-IDA6, Cabot 214 and Haynes 230 [25].…”

Thermal Processing Map and Microstructure Evolution of Inconel 625 Alloy Sheet Based on Plane Strain Compression Deformation

“…Meanwhile, the relationship between σ and Z can be described by power exponential relation at a high stress level, such as Equation ( 4). In the actual production, the hot deformation of Inconel 625 is under the full stress level, and the relationship between σ and Z is shown in Equation (5).…”

“…Due to the stable matrix elements and the large extent of the γ" phase, Inconel 625 has excellent high-temperature strength and structural stability [1][2][3][4]. In addition, Inconel 625 has good machinability and weldability [5,6]. Therefore, Inconel 625 can be easily processed into various components such as plates, bars, pipes, wires, and strips [7].…”

An ANFIS-Mechanistic Simulator of Tool Loads in Ball-End Milling of Layered Metal Materials

“…Ji et al [9] analysed the machinability of Inconel 718 during the micro-milling process. In the research [10] studied the effect of cutting parameters during end milling on Inconel 625 parts manufactured by using the Laser Powder Bed Fusion process. Zhang et al [11] studied the machinability of Ti6Al4V in high-speed dry milling with ceramic flute tools.…”