Machinability of INCONEL718 alloy with a porous microstructure produced by laser melting powder bed fusion at higher energy densities
Authors
Wood, PaulDíaz-Álvarez, Antonio
Díaz-Álvarez, José
Miguélez, María Henar
Rusinek, Alexis
Williams, Gavin
Bahi, Slim
Sienkiewicz, Judyta
Płatek, Paweł
Gunputh, Urvashi Fowdar
wood, paul
Affiliation
University of DerbyUniversity Carlos III of Madrid, Avda. Universidad 30, 28911 Madrid, Spain
Lorraine University, UMR CNRS 7239, 57078 Metz, France
Military University of Technology, gen. Sylwestra Kaliskiego 2, 00-908 Warsaw, Poland
Issue Date
2020-12-15
Metadata
Show full item recordAbstract
Products produced by additive manufacturing (AM) seek to exploit net shape manufacturing by eliminating or minimizing post-process stages such as machining. However, many applications which include turbo machinery components with tight dimensional tolerances and a smooth surface finish will require at least a light machine finishing stage. This paper investigates the machinability of the additively fabricated INCONEL718 (IN718) alloy produced by laser melting powder bed fusion (LM-PBF) with different levels of spherical porosity in the microstructure. The literature suggests that the band width for laser energy density, which combines the various scan process parameters to obtain a low spherical type porosity in the LM-PBF IN718 alloy (~1%), has wide breadth. With the increasing laser energy density and above a threshold, there is a rapid increase in the spherical pore size. In this paper, three tube samples each with different levels of spherical porosity were fabricated by varying the laser energy density for LM-PBF of the IN718 alloy within the stable and higher energy density range and the porosity measured. A low laser energy density was avoided due to balling up, which promotes highly irregular lack of fusion defects and poor consolidation within the alloy microstructure. An orthogonal turning test instrumented, with a three-component dynamometer to measure the cutting forces, was performed on AM produced IN718 tube samples under light cut conditions to simulate a finish machining process. The orthogonal turning tests were also performed on a tube sample obtained from the wrought extruded stock. The machining process parameters, which were studied include varying the cutting speed at three levels, at a fixed feed and under dry cut conditions for a short duration to avoid the tool wear. The results obtained were discussed and a notable finding was the higher rate of built-up-edge formation on the tool tip from the AM samples with a higher porosity and especially at a higher cutting speed. The paper also discusses the mechanisms that underpin the findings.Citation
Wood, P., Díaz-Álvarez, A., Díaz-Álvarez, J., Miguélez, M.H., Rusinek, A., Gunputh, U.F., Williams, G., Bahi, S., Sienkiewicz, J. and Płatek, P., (2020). 'Machinability of INCONEL718 Alloy with a Porous Microstructure Produced by Laser Melting Powder Bed Fusion at Higher Energy Densities'. Materials, 13(24), pp. 1-13.Publisher
MDPIJournal
MaterialsDOI
10.3390/ma13245730PubMed ID
33334067Additional Links
https://www.mdpi.com/1996-1944/13/24/5730Type
ArticleLanguage
enISSN
1996-1944ae974a485f413a2113503eed53cd6c53
10.3390/ma13245730
Scopus Count
The following license files are associated with this item:
- Creative Commons
Except where otherwise noted, this item's license is described as Attribution-NoDerivatives 4.0 International
Related articles
- Effect of Layer-Wise Varying Parameters on the Microstructure and Soundness of Selective Laser Melted INCONEL 718 Alloy.
- Authors: Wang X, Kang J, Wang T, Wu P, Feng T, Zheng L
- Issue date: 2019 Jul 5
- Effects of process parameters on the mechanical properties of additively manufactured Zr-1Mo alloy builds.
- Authors: Sun X, Liu D, Zhou W, Nomura N, Tsutsumi Y, Hanawa T
- Issue date: 2020 Apr
- Influence of Powder Characteristics on Processability of AlSi12 Alloy Fabricated by Selective Laser Melting.
- Authors: Baitimerov R, Lykov P, Zherebtsov D, Radionova L, Shultc A, Prashanth KG
- Issue date: 2018 May 7
- Influence of Homogenization and Solution Treatments Time on the Microstructure and Hardness of Inconel 718 Fabricated by Laser Powder Bed Fusion Process.
- Authors: Fayed EM, Shahriari D, Saadati M, Brailovski V, Jahazi M, Medraj M
- Issue date: 2020 Jun 5
- Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy.
- Authors: Maamoun AH, Xue YF, Elbestawi MA, Veldhuis SC
- Issue date: 2018 Nov 22