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DOI 10.1007/s00170-013-5198-0
ORIGINAL ARTICLE
1 Introduction
Nickel-based superalloys were created in the 1940s primarily
for gas turbine application due to their long-time strength and
toughness at high temperature and more creep resistance
property than available stainless austenitic steels. Nickel
base superalloys are also used for other applications such
as marine equipment, nuclear reactors, etc. They are used in
D. Umbrello (*)
Department of Mechanical, Energy and Management Engineering,
University of Calabria, Via P. Bucci, Cubo 45/C,
87036 Rende, CS, Italy
e-mail: d.umbrello@unical.it
URL: www.unical.it
2 Experimental procedure
Dry orthogonal cutting tests were conducted on Inconel 718
(4299 HV0.05) using a high-speed Mazak computer numerical
measured using a Zygo optical white light interferometrybased surface profilometer. The surface and subsurface hardness
values were also measured on a micro hardness indenter Future
Tech F-7. Additionally, the X-ray diffraction (XRD) Bruker
AXS D8 Discover with a quarter Ellurian cradle sample holder
was used for investigating the microstructural phase composition of the machined surface. The X-ray diffractometer used CuK radiation ( =1.54184 , K 1/K 2 =0.5) from a source
operated at 40 kV and 40 mA. Samples were accordingly
positioned at the center of plate into the X-ray goniometric in
order to ensure a correct beam irradiation. The 2 scans were
carried out between 30 and 100 2. The scan increment was
0.05; the corresponding acquisition time was accordingly
varied.
Cutting speed
0.050
0.075
0.100
50 m/min
60 m/min
70 m/min
ID 1
ID 2
ID 3
ID 4
ID 5
ID 6
ID 7
ID 8
ID 9
b
Grain size on the bulk material
c
Grain size on the bulk material
Fig. 5 Grain size evolution near the machined surface and below it: a
50 m/min, b 60 m/min, and c 70 m/min
Fig. 3 Surface and subsurface hardness profiles at varying of cutting
speed: a 50 m/min, b 60 m/min, and c 70 m/min
Fig. 4 Optical images of the
machined surface and subsurface:
a test ID 1 and b test ID 9
affected featureless
layer
(111)
(200)
(111)
(200)
(220)
(311) (222)
(220)
(311) (222)
(111)
(200)
(004)
(200)
(004)
(220)
(311)
(222)
feed rate are considered (test ID 9): the presence of precipitating phase (004) at 48.5 2 can be observed (Fig. 8).
Precipitating phase , together with , are responsible
for the heat resistance properties of the matrix gamma ()
phase [23]. Gamma double prime, which nucleates and
coarsens on the particles, is a coherent but misfitting and
ordered metastable body-centered tetragonal Ni3Nb structure
with the nickel atoms sitting on the faces and niobium,
titanium, and aluminum on the corners in the body center
sites. Both and enhance the mechanical properties of
the Inconel 718 alloy by anti-phase boundary strengthening
and coherency strains [2426] although the metastability of
the primary strengthening (, gamma double prime) phase
is typically unacceptable for applications above about
650 C. As a result, other more costly and difficult to process
alloys, like Waspalloy, are used in such applications [27].
Fig. 9 XRD peak and width of Ni alloy in a FCC structure at (111) of both machined and as received samples under a different cutting speeds for the
feed rate of 0.1 mm/rev and for b different feed rates for the cutting speed of 70 m/min
4 Conclusions
In this paper, an experimental study is proposed for investigating the dry machining of Inconel 718 alloy in terms of surface
integrity indicators (surface roughness, microhardness, affected layer, grain size and phase changes); consequently, the
following conclusion can be drawn:
&
&
&
&
&
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