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1 – 10 of 299
Article
Publication date: 28 October 2019

Xiaoqing Ni, Liang Zhang, Wenheng Wu, Dexiang Zhu, Decheng Kong, Chaofang Dong and Guoliang Zhu

Laser melting deposition (LMD) is an advanced additive manufacturing (AM) technology without powder waste, and nickel-based alloys with different Nb contents were created one-time…

Abstract

Purpose

Laser melting deposition (LMD) is an advanced additive manufacturing (AM) technology without powder waste, and nickel-based alloys with different Nb contents were created one-time by adjusting the ratio of mixed powders via a dual-feed system. Here, the authors provide a systematic report on the effects of the Nb content on the microstructure, Laves phase segregation and mechanical properties of as-received LMD nickel-based alloys. The effects of the Nb content on the microstructure, precipitation evolution and mechanical properties of the subsequent heat-treated LMD samples are also discussed in this paper.

Design/methodology/approach

Thus, the present research aims to obtain a better understanding of the effect of Nb content on the microstructural and mechanical properties of the as-received LMD Inconel 718 alloys through high-throughput sample fabrication. The microstructures were characterized by scanning electron microscopy and energy-dispersive spectroscopy, electron back-scattered diffraction and transmission electron microscopy methods. The mechanical properties were obtained from compressive tests and nano-indentation tests. Electrochemical tests, including electrochemical impedance spectroscopy and potentiodynamic polarizations, were carried out to evaluate the durability of the Inconel 718 alloys. Results can provide a factual basis for future applications of the functionally graded by AM technology.

Findings

The grain size of the as-received LMD Inconel 718 alloys decreased with the Nb content. The Laves phase distribution at the macro level was relatively uniform and the Laves phase exhibited a 1.5-fold nano-hardness compared with the matrix. The strength improvement for the as-received LMD Inconel 718 alloys with Nb content was attributed to grain refinement and enhancement of the Laves phase in terms of both hardness and content. Meanwhile, the corrosion resistance increased with the increase of the Nb content, especially for the pitting potential, which was attributed to the optimization of carbide precipitates due to the strong affinity between niobium and carbon.

Originality/value

The results provide a factual basis for the Nb content effect in LMD nickel-based alloys, and this method can greatly promote the development of new materials. The authors believe that this study makes a significant contribution to the literature and is suitable for publication.

Details

Anti-Corrosion Methods and Materials, vol. 67 no. 1
Type: Research Article
ISSN: 0003-5599

Keywords

Article
Publication date: 16 October 2020

Sahil Sharma, Umesh Kumar Vates and Amit Bansal

In the current exploration, the machinability of three different nickel-based super-alloy materials (Inconel 625, Inconel 718 and Nimonic 90) was experimentally investigated by…

Abstract

Purpose

In the current exploration, the machinability of three different nickel-based super-alloy materials (Inconel 625, Inconel 718 and Nimonic 90) was experimentally investigated by using a die-sinking electrical discharge machining (EDM). The effect of changing important input process parameters such as pulse on time (Ton), off time (Toff), peak current (Ip) and tool rotation (TR) was investigated to get optimum machining characteristics such as material removal rate, roughness, electrode wear rate and overcut.

Design/methodology/approach

Experimentation has been performed by using Taguchi L9 orthogonal design. An integrated route of fuzzy and grey relational analysis approach with Taguchi’s philosophy has been intended for the simultaneous optimization of machining output parameters.

Findings

The most approbatory factors for machining setting have been attained as: (Ton = 100 µs, Toff = 25 µs, Ip = 14 A, TR = 725 rpm) for machining of Inconel 625 and Inconel 718; and (Ton = 100 µs, Toff = 75 µs, Ip = 14 A, TR = 925 rpm) for machining of the Nimonic 90 material. Peak current has been observed as an overall influencing factor to achieve better machining process. Microstructural study through SEM has also been carried out to figure out the surface morphology for the EDMed Ni-based super alloys.

Originality/value

The proposed machining variables and methodology has never been presented for Nimonic 90 alloy on die-sinking EDM.

Details

World Journal of Engineering, vol. 18 no. 1
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 11 January 2022

Tushar Sonar, Visvalingam Balasubramanian, Sudersanan Malarvizhi, Thiruvenkatam Venkateswaran and Dhenuvakonda Sivakumar

The primary objective of this investigation is to optimize the constricted arc tungsten inert gas (CA-TIG) welding parameters specifically welding current (WC), arc constriction…

Abstract

Purpose

The primary objective of this investigation is to optimize the constricted arc tungsten inert gas (CA-TIG) welding parameters specifically welding current (WC), arc constriction current (ACC), ACC frequency (ACCF) and CA traverse speed to maximize the tensile properties of thin Inconel 718 sheets (2 mm thick) using a statistical technique of response surface methodology and desirability function for gas turbine engine applications.

Design/methodology/approach

The four factor – five level central composite design (4 × 5 – CCD) matrix pertaining to the minimum number of experiments was chosen in this investigation for designing the experimental matrix. The techniques of numerical and graphical optimization were used to find the optimal conditions of CA-TIG welding parameters.

Findings

The thin sheets of Inconel 718 (2 mm thick) can be welded successfully using CA-TIG welding process without any defects. The joints welded using optimized conditions of CA-TIG welding parameters showed maximum of 99.20%, 94.45% and 73.5% of base metal tensile strength, yield strength and elongation.

Originality/value

The joints made using optimized CA-TIG welding parameters disclosed 99.20% joint efficiency which is comparatively 20%–30% superior than conventional TIG welding process and comparable to costly electron beam welding and laser beam welding processes. The parametric mathematical equations were designed to predict the tensile properties of Inconel 718 joints accurately with a confidence level of 95% and less than 4.5% error. The mathematical relationships were also developed to predict the tensile properties of joints from the grain size (secondary dendritic arm spacing-SDAS) of fusion zone microstructure.

Details

Aircraft Engineering and Aerospace Technology, vol. 94 no. 5
Type: Research Article
ISSN: 1748-8842

Keywords

Article
Publication date: 7 February 2020

Xianping Wei and Wen Jie Zheng

This paper aims to expand the application area of Inconel 718 alloy in marine environment, the sensitivity of pitting corrosion should be analyzed and discussed, especially the…

Abstract

Purpose

This paper aims to expand the application area of Inconel 718 alloy in marine environment, the sensitivity of pitting corrosion should be analyzed and discussed, especially the effect of block carbides.

Design/methodology/approach

Effect of carbides on the sensitivity of pitting corrosion for Inconel 718 alloy was carried out at 30°C in 3.5% NaCl solution using dynamic electrochemical impedance spectroscopy and anodic polarization techniques. In addition, the initiation of pitting corrosion was investigated by immersion test in 0.05 M HCl + 6% FeCl3 solution.

Findings

As a result, the precipitation of carbides, as the initiation of pitting corrosion, increased pitting corrosion susceptibility, especially the block carbides could lead to deep-spalling. Within that process, temperature and potential acted as the main controlling factors, and the effect of the latter was more distinct.

Originality/value

The initiation of pitting corrosion was revealed by the immersion test. The mechanism of pitting corrosion was analyzed and discussed.

Details

Anti-Corrosion Methods and Materials, vol. 67 no. 2
Type: Research Article
ISSN: 0003-5599

Keywords

Article
Publication date: 30 April 2019

Pragat Singh, J.S. Dureja, Harwinder Singh and Manpreet S. Bhatti

This study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304…

Abstract

Purpose

This study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304 (SS-304) (Ni-Cr alloys).

Design/methodology/approach

Machining of Ni-Cr-based alloys is very challenging as these exhibit lower thermal conductivity and rapid work hardening. So, these cannot be machined dry, and a suitable cutting fluid has to be used. To improve the thermal conductivity of cutting fluid, multi-walled carbon nanotubes (MWCNTs) were added to the soybean oil and used with MQL. This study attempts to compare tool wear of coated carbide inserts during face milling of Inconel-625 and SS-304 under dry, flooded and NMQL conditions. The machining performance of both materials, i.e. Inconel-625 and SS-304, has been compared on the basis of tool wear behavior evaluated using scanning electron microscopy-energy dispersive spectroscopy.

Findings

The results indicate higher tool wear and lower tool life during machining of Inconel-625 as compared to SS-304. Machining of Inconel-625 exhibited non-consistent tool wear behavior. The tool failure modes experienced during dry machining are discrete fracture, cracks, etc., which are completely eliminated with the use of NMQL machining. In addition, less adhesion wear and abrasion marks are noticed as compared to dry and flooded machining, thereby enhancing the tool life.

Research limitations/implications

Inconel-625 and SS-304 have specific applications in aircraft and aerospace industry, where sculptured surfaces of the turbine blades are machined. The results of current investigation will provide a rich data base for effective machining of both materials under variety of machining conditions.

Originality/value

The literature review indicated that majority of research work on MQL machining has been carried out to explore machining of Ni-Cr alloys such as Inconel 718, Inconel 800, AISI4340, AISI316, AISI1040, AISI430, titanium alloys, hardened steel alloys and Al alloys. Few researchers have explored the suitability of nanofluids and vegetable oil-based cutting fluids in metal cutting operation. However, no literature is available on face milling using nanoparticle-based MQL during machining Inconel-625 and SS-304. Therefore, experimental investigation was conducted to examine the machining performance of NMQL during face milling of Inconel-625 and SS-304 by using soybean oil (vegetable oil) with MWCNTs to achieve ecofriendly machining.

Article
Publication date: 13 April 2022

Qingyong Chen, Guilan Wang, Haiou Zhang and Runsheng Li

The purpose of this paper is to study the influence of different rolling deformation parameters on the morphology, microstructure and mechanical properties of Inconel 718

Abstract

Purpose

The purpose of this paper is to study the influence of different rolling deformation parameters on the morphology, microstructure and mechanical properties of Inconel 718 superalloy in hybrid plasma arc and micro-rolling (HPAMR) additive manufacturing.

Design/methodology/approach

In this paper, different deformation strains are designed, which are as-deposited, 15% and 30%. Two straight walls are fabricated by HPAMR for each kind of deformation. One wall underwent post-deposition heat treatment, and the other wall is treated without heat treatment. These samples are further investigated to evaluate the effects of deformation on the morphology, microstructure and mechanical properties.

Findings

As compared to as-deposited samples, the morphology can be significantly improved, the generation of defects and microporosity inside the alloy can be suppressed, and finer equiaxed crystals can be obtained with deformation of 30%. With heat treatment and 30% deformation, the Laves phase at the grain boundary is completely disappearing, more γ” and γ' strengthening phase is precipitated in the crystal and the size of the strengthening phase is smaller. Mechanical properties have been significantly improved.

Practical implications

HPAMR technology is used to successfully manufacture Inconel 718 superalloy aero-engine casing.

Originality/value

Compared with plasma arc additive manufacturing, HPAMR technology adds a rolling process, which can effectively improve the morphology of walls, refine internal grains, eliminate defects and microporosity, increase precipitation of strengthening phase and improve mechanical properties. It provides an optional manufacturing method for the integrated manufacturing of Inconel 718 parts.

Details

Rapid Prototyping Journal, vol. 28 no. 8
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 7 October 2021

Amrita Maddamasetty, Kamesh Bodduru, Siva Bevara, Rukmini Srikant Revuru and Sanjay Kumar

Inconel 718 is difficult to machine due to its high toughness and study hardenability. Though the use of cutting fluids alleviates the problem, it is not sustainable. So, supply…

Abstract

Purpose

Inconel 718 is difficult to machine due to its high toughness and study hardenability. Though the use of cutting fluids alleviates the problem, it is not sustainable. So, supply of a small quantity of specialized coolant to the machining zone or use of a solid lubricant is a possible solution. The purpose of the present work is to improve machinability of Inconel718 using graphene nanoplatelets.

Design/methodology/approach

In the present study, graphene is used in the machining of Inconel 718 alloy. Graphene is applied in the following two forms: as a solid lubricant and as an inclusion in cutting fluid. Graphene-based self-lubricating tool and graphene added nanofluids are prepared and applied to turning of Inconel 718 at varying cutting velocities. Performances are compared by measuring cutting forces, cutting temperature, tool wear and surface roughness.

Findings

Graphene, in both forms, showed superior performance compared to dry machining. In total, 0.3 Wt.% graphene added nanofluids showed the lowest cutting tool temperature and flank wear with 44.95% and 83.37% decrease, respectively, compared to dry machining and lowest surface roughness, 0.424 times compared to dry machining at 87 m/min.

Originality/value

Graphene could improve the machinability of Inconel 718 when used in tools as a solid lubricant and also when used as a dispersant in cutting fluid. Graphene used as a dispersant in cutting fluid is found to be more effective.

Details

World Journal of Engineering, vol. 19 no. 4
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 1 April 2001

R.J. Smith, G.J. Lewi and D.H. Yates

Since the development of the Nimonic1 alloys for Sir Frank Whittle’s first jet engine, Henry Wiggin Ltd, now part of Special Metals Corporation, has been involved with the design…

3731

Abstract

Since the development of the Nimonic1 alloys for Sir Frank Whittle’s first jet engine, Henry Wiggin Ltd, now part of Special Metals Corporation, has been involved with the design and improvement of nickel alloys for aerospace engineering. Whilst much of this work continues to be in relation to alloys for the high strength/high temperature applications of turbine blades, discs, seals, rings and casings of aero engines, nickel alloys are being utilised for other key aerospace engineering areas such as tooling for composite manufacture. The focus of this paper is on four recent developments in nickel alloys for aerospace engineering, namely: disc alloys; low expansion superalloys; Inconel alloy 718SPF – a nickel base superalloy capable of being superplastically formed; Nilo (low expansion alloys) for composite tooling.

Details

Aircraft Engineering and Aerospace Technology, vol. 73 no. 2
Type: Research Article
ISSN: 0002-2667

Keywords

Article
Publication date: 14 March 2016

Xiaohong Lu, Zhenyuan Jia, Hua Wang, Likun Si, Yongyun Liu and Wenyi Wu

– The paper aims to study the wear and breakage characteristics of coated carbide cutting tools through micro-milling slot experiments on superalloy Inconel 718.

1106

Abstract

Purpose

The paper aims to study the wear and breakage characteristics of coated carbide cutting tools through micro-milling slot experiments on superalloy Inconel 718.

Design/methodology/approach

During the micro-milling process, the wear and breakage appearance on the rake face and flank face of the cutting tools, as well as the failure mechanism, have been studied. Furthermore, the wear and breakage characteristics of the micro-cutting tools have been compared with the traditional milling on Inconel 718.

Findings

The main failure forms of the micro tool when micro-milling Inconel 718 were tool tip breakage and coating shed on the rake and flank faces of the cutting tool and micro-crack blade. The main causes of tool wear were synthetic action of adhesive abrasion, diffusion wear and oxidation wear, while the causes of abrasive wear were not obvious.

Practical implications

The changing trend in tool wear during the micro-milling process and the main reasons of the tool wear are studied. The findings will facilitate slowing down the tool wear and prolonging the tool life during micro-milling Inconel718.

Originality/value

The results of this paper can help slow down the tool wear and realize high efficiency, high precision and economical processing of small workpiece or structure of the nickel-based superalloy.

Details

Industrial Lubrication and Tribology, vol. 68 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 25 January 2024

Talwinder Singh

The purpose of this paper, an experimental study, is to investigate the optimal machining parameters for turning of nickel-based superalloy Inconel 718 under eco-friendly…

Abstract

Purpose

The purpose of this paper, an experimental study, is to investigate the optimal machining parameters for turning of nickel-based superalloy Inconel 718 under eco-friendly nanofluid minimum quantity lubrication (NMQL) environment to minimize cutting tool flank wear (Vb) and machined surface roughness (Ra).

Design/methodology/approach

The central composite rotatable design approach under response surface methodology (RSM) is adopted to prepare a design of experiments plan for conducting turning experiments.

Findings

The optimum value of input turning parameters: cutting speed (A), feed rate (B) and depth of cut (C) is found as 79.88 m/min, 0.1 mm/rev and 0.2 mm, respectively, with optimal output response parameters: Vb = 138.633 µm and Ra = 0.462 µm at the desirability level of 0.766. Feed rate: B and cutting speed: A2 are the leading model variables affecting Vb, with a percentage contribution rate of 12.06% and 43.69%, respectively, while cutting speed: A and feed rate: B are the significant factors for Ra, having a percentage contribution of 38.25% and 18.03%, respectively. Results of validation experiments confirm that the error between RSM predicted and experimental observed values for Vb and Ra is 3.28% and 3.75%, respectively, which is less than 5%, thus validating that the formed RSM models have a high degree of conformity with the obtained experimental results.

Practical implications

The outcomes of this research can be used as a reference machining database for various metal cutting industries to establish eco-friendly NMQL practices during the turning of superalloy Inconel 718 to enhance cutting tool performance and machined surface integrity.

Originality/value

No study has been communicated till now on the turning of Inconel 718 under NMQL conditions using olive oil blended with multi-walled carbon nanotubes-based nanofluid.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2023-0317/

Details

Industrial Lubrication and Tribology, vol. 76 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

1 – 10 of 299