A review on the progress towards improvement in surface integrity of Inconel 718 under high pressure and flood cooling conditions

• Published in: International journal of advanced manufacturing technology 2017-07, Vol.91 (1-4), p.107-125
• Main Authors: Mohsan, Aziz UI Hassan, Liu, Zhanqiang, Padhy, G. K.
• Format: Article
• Language: English
• Subjects: Aerospace engines; Aircraft components; Alloys; CAE) and Design; Component reliability; Computer-Aided Engineering (CAD; Coolants; Cooling; Cooling effects; Corrosion resistance; Corrosive wear; Creep strength; Cryogenic cooling; Dry machining; Engine materials; Engineering; High resistance; High temperature; Industrial and Production Engineering; Integrity; Literature reviews; Lubrication; Machining; Materials selection; Mechanical Engineering; Media Management; Metallurgy; Nickel base alloys; Original Article; Productivity; Residual stress; Surface layers; Surface roughness; Sustainability; Turbine engines; Viability; Wear resistance
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-016-9737-3

While dry machining is an emerging trend for maintaining sound surface integrity of materials, it poses cost-effective productivity as a major concern in industries. In the machining of difficult-to-cut materials such as aerospace turbine engine materials, application of coolants is indispensable. Flood cooling is the most conventional cooling method employed in the machining process although alternative cooling technologies like minimum quantity lubrication (MQL), cryogenic cooling, solid lubrication, and high-pressure coolant (HPC) machining are also in wide use. Despite being sustainable, machining processes based on MQL and cryogenic cooling present questionable viability with regard to their control in industries. Besides the sustainability and productivity, surface integrity of the machined components influences its life in service while the cooling methods have an obvious effect on surface integrity. Therefore, cooling and surface integrity are of significant importance towards the safety, reliability, and durability of the component in service. Surface integrity may be accessed through three components, surface texture or surface roughness, metallurgical layer formation, and residual stresses. Machining of aerospace turbine engine materials such as Ti and Ni alloys requires proper validation with respect to the surface integrity. Among the Ni-based superalloys, Inconel 718 is a candidate material for aerospace applications because of its high resistance to wear and corrosion and higher creep strength at elevated temperatures. This paper presents a detailed review on the elucidation and visualization of current status of surface roughness, subsurface damage, and residual stresses during the turning of Inconel 718 under high pressure and flood cooling conditions. Based on the review, a checklist has been developed according to the scenario of entire literature review.