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Machining and Finishing of Nickel and Titanium Alloys

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A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (31 October 2018) | Viewed by 68600

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Prof. Dr. Naiara Ortega

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Guest Editor

Metrology lab CFAA; Department of Mechanical Engineering, University of the Basque Country; EIB, Alameda de Urquijo s/n, 48013 Bilbao, Spain
Interests: metrology; NDTs; welding; coatings; machining; manufacturing of aeroengine components; vibrations in manufacturing processes
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Prof. Dr. Luis Norberto López De Lacalle

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The Aeronautics Advanced Manufacturing Center-CFAA, 48170 Zamudio, Biscay, Spain
Interests: manufacturing process
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Dear Coleagues,

Nickel and titanium alloys are high-temperature resistant alloys, essential in many applications. Gas turbines, fuel nozzles, heat treating fixtures, and furnace muffles are some examples where these materials must stand up to high heat, extreme oxidation potential, and cycling. However, these materials are also characterized by their low machinability. With the aim of dealing with this drawback, new machining and finishing processes are being developed. They enable optimized component shapes, surface finishing and surface integrity for specific applications.

Problems related to machining of components of nickel and titanium alloys are far from being solved. New cooling systems, tools and tool’s coatings, new abrasive processes and strategies are being investigated deeply. In addition, friendly and sustainable processes are including in the workshops.

The aim of this Special Issue is to highlight recent advancements related to machining and finishing of nickel and titanium based alloys mainly for aeroengine components. Machines, processes, assisted processes and new tools are now in a rapid evolution.

Prof. Dr. Naiara Ortega
Prof. Dr. Luis Norberto López de Lacalle
Guest Editors

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Keywords

Machining of superalloys
Laser additive manufacturing
Abrasive machining and finishing
New emerging alloys: Gamma TiAl processing
Machinability
Surface integrity
Modeling of machining and grinding processes
Ceramics and PCBN: new tools
Integral blade rotors: the challenge
Cutting tools for the group ISO S alloys

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Published Papers (10 papers)

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Research

15 pages, 6864 KiB

Open AccessArticle

A Study on the Machining Characteristics of Curved Workpiece Using Laser-Assisted Milling with Different Tool Paths in Inconel 718

by Eun Jung Kim and Choon Man Lee

Metals 2018, 8(11), 968; https://doi.org/10.3390/met8110968 - 20 Nov 2018

Cited by 13 | Viewed by 4567

Abstract

Difficult-to-cut materials are being increasingly used in many industries because of their superior properties, including high corrosion resistance, heat resistance and specific strength. However, these same properties make the materials difficult to machine using conventional machining techniques. Laser-assisted milling (LAM) is one of the effective method for machining difficult-to-cut materials. In laser-assisted milling, the machining occur after the workpiece is locally preheated using a laser heat source. Laser-assisted milling has been studied by many researchers on flat workpiece or micro end-milling. However, there is no research on the curved shape using laser assisted milling. This study investigated the use of laser-assisted milling to machine a three-dimensional curved shape workpiece based on NURBS (Non-uniform rational b-spline). A machining experiment was performed on Inconel 718 using different tool paths (ramping, contouring) under various machining conditions. Finite elements analysis was conducted to determine the depth of cut. Cutting force, specific cutting energy and surface roughness characteristics were measured, analyzed and compared for conventional and LAM machining. LAM significantly improved these machining characteristics, compared to conventional machining. There results can be applied to the laser-assisted milling of various three-dimensional shapes. Full article

(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)

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12 pages, 2636 KiB

Open AccessArticle

Finishing Turning of Ni Superalloy Haynes 282

by José Díaz-Álvarez, Antonio Díaz-Álvarez, Henar Miguélez and José Luis Cantero

Metals 2018, 8(10), 843; https://doi.org/10.3390/met8100843 - 18 Oct 2018

Cited by 15 | Viewed by 4924

Abstract

Nickel-based superalloys are widely used in the aeronautical industry, especially in components requiring excellent corrosion resistance, enhanced thermal fatigue properties, and thermal stability. Haynes 282 is a nickel-based superalloy that was developed to improve the low weldability, formability, and creep strength of other γ’-strengthened Ni superalloys. Despite the industrial interest in Haynes 282, there is a lack of research that is focused on this alloy. Moreover, it is difficult to find studies dealing with the machinability of Haynes 282. Although Haynes 282 is considered an alloy with improved formability when compared with other nickel alloys, its machining performance should be analyzed. High pressure and temperature localized in the cutting zone, the abrasion generated by the hard carbides included in the material, and the tendency toward adhesion during machining are phenomena that generate extreme thermomechanical loading on the tool during the cutting process. Excessive wear results in reduced tool life, leading to frequent tool change, low productivity, and a high consumption of energy; consequentially, there are increased costs. With regard to tool materials, cemented carbide tools are widely used in different applications, and carbide is a recommended cutting material for turning Haynes 282, for both finishing and roughing operations. This work focuses on the finishing turning of Haynes 282 using coated carbide tools with conventional coolant. Machining forces, surface roughness, tool wear, and tool life were quantified for different cutting speeds and feeds. Full article

(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)

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17 pages, 4405 KiB

Open AccessArticle

PCBN Performance in High Speed Finishing Turning of Inconel 718

by José Díaz-Álvarez, Víctor Criado, Henar Miguélez and José Luis Cantero

Metals 2018, 8(8), 582; https://doi.org/10.3390/met8080582 - 26 Jul 2018

Cited by 24 | Viewed by 4772

Abstract

Inconel 718 is a Ni superalloy widely used in high responsibility components requiring excellent mechanical properties at high temperature and elevated corrosion resistance. Inconel 718 is a difficult to cut material due to the elevated temperature generated during cutting, its low thermal conductivity, and the strong abrasive tool wear during cutting process. Finishing operations should ensure surface integrity of the component commonly requiring the use of hard metal tools with sharp tool edges and moderate cutting speeds. Polycrystalline cubic boron nitride (PCBN) tools recently developed an enhanced toughness suitable for these final operations. This paper focuses on the study of PCBN tools performance in finishing turning of Inconel 718. Several inserts representative of different manufacturers were tested and compared to a reference carbide tool. The evolution of tool wear, surface roughness, and cutting forces was analyzed and discussed. PCBN tools demonstrated their suitability for finishing operations, presenting reasonable removal rates and surface quality. Full article

(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)

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12 pages, 4702 KiB

Open AccessArticle

Hole Making by Electrical Discharge Machining (EDM) of γ-TiAl Intermetallic Alloys

by Aitor Beranoagirre, Gorka Urbikain, Amaia Calleja and Luis Norberto López de Lacalle

Metals 2018, 8(7), 543; https://doi.org/10.3390/met8070543 - 14 Jul 2018

Cited by 16 | Viewed by 4275

Abstract

Due to their excellent strength-to-weight ratio and corrosion and wear resistance, γ-TiAl alloys are selected for aerospace and automotive applications. Since these materials are difficult to cut and machine by conventional methods, this study performed drilling tests using Electro Discharge Machining (EDM) to compare the machinability between two different types of γ-TiAl: extruded MoCusi and ingot MoCuSi. Different electrode materials and machining parameters were tested and wear, surface hardness, roughness and integrity were analyzed. The results indicate that extruded MoCuSi is preferable over MoCuSi ingots. Full article

(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)

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17 pages, 5843 KiB

Open AccessArticle

Five-Axis Milling of Large Spiral Bevel Gears: Toolpath Definition, Finishing, and Shape Errors

by Álvaro Álvarez, Amaia Calleja, Naiara Ortega and Luis Norberto López De Lacalle

Metals 2018, 8(5), 353; https://doi.org/10.3390/met8050353 - 15 May 2018

Cited by 55 | Viewed by 11164

Abstract

In this paper, a five-axis machining process is analyzed for large spiral-bevel gears, an interesting process for one-of-kind manufacturing. The work is focused on large sized spiral bevel gears manufacturing using universal multitasking machines or five-axis milling centers. Different machining strategies, toolpath patterns, and parameters are tested for both gear roughing and finishing operations. Machining time, tools’ wear, and gear surface are analyzed in order to determine which are the best strategies and parameters for large modulus gear manufacturing on universal machines. The case study results are discussed in the last section, showing the capacity of a universal five-axis milling for this niche. Special attention was paid to the possible affectations of the metal surfaces, since gear durability is very sensitive to thermo-mechanical damage, affected layers, and flank gear surface state. Full article

(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)

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24 pages, 9017 KiB

Open AccessArticle

An Analysis of Electroplated cBN Grinding Wheel Wear and Conditioning during Creep Feed Grinding of Aeronautical Alloys

by Gorka Vidal, Naiara Ortega, Héctor Bravo, Mirentxu Dubar and Haizea González

Metals 2018, 8(5), 350; https://doi.org/10.3390/met8050350 - 14 May 2018

Cited by 25 | Viewed by 7525

Abstract

Cubic boron nitride (cBN), in addition to diamond, is one of the two superabrasives most commonly used for grinding hard materials such as ceramics or difficult-to-cut metal alloys such as nickel-based aeronautical alloys. In the manufacturing process of turbine parts, electroplated cBN wheels are commonly used under creep feed grinding (CFG) conditions for enhancing productivity. This type of wheel is used because of its chemical stability and high thermal conductivity in comparison with diamond, as it maintains its shape longer. However, these wheels only have one abrasive layer, for which wear may lead to vibration and thermal problems. The effect of wear can be partially solved through conditioning the wheel surface. Silicon carbide (SiC) stick conditioning is commonly used in the industry due to its simplicity and good results. Nevertheless, little work has been done on the understanding of this conditioning process for electroplated cBN wheels in terms of wheel topography and later wheel performance during CFG. This work is focused, firstly, on detecting the main wear type and proposing a manner for its measurement and, secondly, on analyzing the effect of the conditioning process in terms of topographical changes and power consumption during grinding before and after conditioning. Full article

(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)

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11 pages, 2808 KiB

Open AccessArticle

Manufacturing and Characterization of NiTi Alloy with Functional Properties by Selective Laser Melting

by Shih-Fu Ou, Bou-Yue Peng, Yi-Cheng Chen and Meng-Hsiu Tsai

Metals 2018, 8(5), 342; https://doi.org/10.3390/met8050342 - 11 May 2018

Cited by 53 | Viewed by 6108

Abstract

In this study, an optimal selective laser melting (SLM) process for manufacturing dense NiTi alloy with pseudoelasticity and shape-memory capability was proposed. The microstructure, phase-transformation temperature, shape memory capability, and pseudoelasticity were investigated by scanning electron microscopy, X-ray diffraction, differential scanning calorimetry, and bending and tensile tests. NiTi powder with a particle size > 45 μm was selected for the subsequent SLM process, because it exhibited a Ni/Ti ratio of ~1 and a lower oxygen content than powders with smaller particle sizes. A thin-walled disk (0.48 mm thick) and cuboid samples (5 mm thick) were prepared for investigating the variation in the homogeneity of the microstructure. The thin-walled SLM-NiTi sample exhibited a marginally inhomogeneous microstructure between layers, and defects existed in the previously formed side. The cuboid SLM-NiTi sample was fabricated without undesirable secondary phases, and it exhibited a 100% shape-recovery rate under 2% bending strain and completely pseudoelastic under 3% strain. Also, the SLM-NiTi exhibited lower phase-transformation temperatures and a broader phase-transformation range than the original NiTi. The phase-transformation range can be reduced by annealing. Full article

(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)

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17 pages, 3876 KiB

Open AccessArticle

High Speed Finish Turning of Inconel 718 Using PCBN Tools under Dry Conditions

by José Luis Cantero, José Díaz-Álvarez, Diego Infante-García, Marcos Rodríguez and Víctor Criado

Metals 2018, 8(3), 192; https://doi.org/10.3390/met8030192 - 17 Mar 2018

Cited by 33 | Viewed by 8858

Abstract

Inconel 718 is a superalloy, considered one of the least machinable materials. Tools must withstand a high level of temperatures and pressures in a very localized area, the abrasiveness of the hard carbides contained in the Inconel 718 microstructure and the adhesion tendency during its machining. Mechanical properties along with the low thermal conductivity become an important issue for the tool wear. The finishing operations for Inconel 718 are usually performed after solution heat treatment and age hardening of the material to give the superalloy a higher level of hardness. Carbide tools, cutting fluid (at normal or high pressures) and low cutting speed are the main recommendations for finish turning of Inconel 718. However, dry machining is preferable to the use of cutting fluids, because of its lower environmental impact and cost. Previous research has concluded that the elimination of cutting fluid in these processes is feasible when using hard carbide tools. Recent development of new PCBN (Polycrystalline Cubic Boron Nitride) grades for cutting tools with higher tenacity has allowed the application of these tool grades in the finishing operations of Inconel 718. This work studies the performance of commercial PCBN tools from four different tool manufacturers as well as an additional grade with equivalent performance during finish turning of Inconel 718 under dry conditions. Wear tests were carried out with different cutting conditions, determining the evolution of machining forces, surface roughness and tool wear. It is concluded that it is not industrially viable the high-speed finishing of Inconel 718 in a dry environment. Full article

(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)

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11 pages, 9024 KiB

Open AccessFeature PaperArticle

Super Abrasive Machining of Integral Rotary Components Using Grinding Flank Tools

by Haizea González, Amaia Calleja, Octavio Pereira, Naiara Ortega, L. Norberto López de Lacalle and Michael Barton

Metals 2018, 8(1), 24; https://doi.org/10.3390/met8010024 - 1 Jan 2018

Cited by 81 | Viewed by 8259

Abstract

Manufacturing techniques that are applied to turbomachinery components represent a challenge in the aeronautic sector. These components require high resistant super-alloys in order to satisfy the extreme working conditions they have to support during their useful life. Besides, in the particular case of Integrally Bladed Rotors (IBR), usually present complex geometries that need to be roughed and finished by milling and grinding processes, respectively. In order to improve their manufacturing processes, Super Abrasive Machining (SAM) is presented as a solution because it combines the advantages of the use of grinding tools with milling feed rates. However, this innovative technique usually needed high tool rotary speed and pure cutting oils cooling. These issues implied that SAM technique was not feasible in conventional machining centers. In this work, these matters were tackled and the possibility of using SAM in these five-axis centers with emulsion coolants was achieved. To verify this approach, Inconel 718 single blades with non-ruled surfaces were manufactured with Flank-SAM technique and conventional milling process, analyzing cutting forces, surface roughness, and dimension accuracy in both cases. The results show that SAM implies a suitable, controllable, and predictable process to improve the manufacture of aeronautical critical components, such as IBR. Full article

(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)

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15 pages, 2436 KiB

Open AccessArticle

An Investigation of the Micro-Electrical Discharge Machining of Nickel-Titanium Shape Memory Alloy Using Grey Relations Coupled with Principal Component Analysis

by Mustufa Haider Abidi, Abdulrahman M. Al-Ahmari, Arshad Noor Siddiquee, Syed Hammad Mian, Muneer Khan Mohammed and Mohammed Sarvar Rasheed

Metals 2017, 7(11), 486; https://doi.org/10.3390/met7110486 - 9 Nov 2017

Cited by 34 | Viewed by 6127

Abstract

Shape memory alloys (SMAs) are advanced engineering materials which possess shape memory effects and super-elastic properties. Their high strength, high wear-resistance, pseudo plasticity, etc., makes the machining of Ni-Ti based SMAs difficult using traditional techniques. Among all non-conventional processes, micro-electric discharge machining (micro-EDM) is considered one of the leading processes for micro-machining, owing to its high aspect ratio and capability to machine hard-to-cut materials with good surface finish.The selection of the most appropriate input parameter combination to provide the optimum values for various responses is very important in micro-EDM. This article demonstrates the methodology for optimizing multiple quality characteristics (overcut, taper angle and surface roughness) to enhance the quality of micro-holes in Ni-Ti based alloy, using the Grey–Taguchi method. A Taguchi-based grey relational analysis coupled with principal component analysis (Grey-PCA) methodology was implemented to investigate the effect of three important micro-EDM process parameters, namely capacitance, voltage and electrode material.The analysis of the individual responses established the importance of multi-response optimization. The main effects plots for the micro-EDM parameters and Analysis of Variance (ANOVA) indicate that every parameter does not produce same effect on individual responses, and also that the percent contribution of each parameter to individual response is highly varied. As a result, multi-response optimization was implemented using Grey-PCA. Further, this study revealed that the electrode material had the strongest effect on the multi-response parameter, followed by the voltage and capacitance. The main effects plot for the Grey-PCA shows that the micro-EDM parameters “capacitance” at level-2 (i.e., 475 pF), “discharge voltage” at level-1 (i.e., 80 V) and the “electrode material” Cu provided the best multi-response. Full article

(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)

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