Machinability of INCONEL718 alloy with a porous microstructure produced by laser melting powder bed fusion at higher energy densities

Journal article


Wood, Paul K, Díaz-Álvarez, Antonio, Díaz-Álvarez, José, Miguélez, María Henar, Rusinek, Alexis, Williams, Gavin, Bahi, Slim, Sienkiewicz, Judyta, Płatek, Paweł, Gunputh, Urvashi Fowdar and wood, paul 2020. Machinability of INCONEL718 alloy with a porous microstructure produced by laser melting powder bed fusion at higher energy densities. Materials. 13 (24). https://doi.org/10.3390/ma13245730
AuthorsWood, Paul K, Díaz-Álvarez, Antonio, Díaz-Álvarez, José, Miguélez, María Henar, Rusinek, Alexis, Williams, Gavin, Bahi, Slim, Sienkiewicz, Judyta, Płatek, Paweł, Gunputh, Urvashi Fowdar and wood, paul
Abstract

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.

KeywordsINCONEL718; SLM; additive manufacturing; machining; powder bed fusion; spherical porosity
Year2020
JournalMaterials
Materials (Basel, Switzerland)
Journal citation13 (24)
PublisherMDPI
ISSN1996-1944
Digital Object Identifier (DOI)https://doi.org/10.3390/ma13245730
Web address (URL)http://hdl.handle.net/10545/625514
http://creativecommons.org/licenses/by-nd/4.0/
hdl:10545/625514
Publication dates15 Dec 2020
Publication process dates
Deposited15 Jan 2021, 10:41
Accepted13 Dec 2020
Rights

Attribution-NoDerivatives 4.0 International

Place of publicationSwitzerland
ContributorsUniversity of Derby, University Carlos III of Madrid, Avda. Universidad 30, 28911 Madrid, Spain, Lorraine University, UMR CNRS 7239, 57078 Metz, France and Military University of Technology, gen. Sylwestra Kaliskiego 2, 00-908 Warsaw, Poland
File
File Access Level
Open
File
File Access Level
Open
File
File Access Level
Open
Permalink -

https://repository.derby.ac.uk/item/94z72/machinability-of-inconel718-alloy-with-a-porous-microstructure-produced-by-laser-melting-powder-bed-fusion-at-higher-energy-densities

Download files

  • 20
    total views
  • 1
    total downloads
  • 0
    views this month
  • 0
    downloads this month

Export as

Related outputs

Microstructure and geometry effects on the compressive behavior of LPBF-manufactured inconel 718 honeycomb structures
Voyiadjis, G. z., Znemah, R. A. and Paul Wood 2023. Microstructure and geometry effects on the compressive behavior of LPBF-manufactured inconel 718 honeycomb structures. Journal of Materials Research and Technology. 24, pp. 1562-1578. https://doi.org/10.1016/j.jmrt.2023.03.093
On the Lubricity and Comparative Life Cycle of Biobased Synthetic and Mineral Oil Emulsions in Machining Titanium Ti-6Al-4V at Low Cutting Speed
Wood, P., Boud, F., Carter, W., Varasteh, H., Gunputh, U., Pawlik, M., Clementson, J., Lu, Y. and Hossain, S. 2022. On the Lubricity and Comparative Life Cycle of Biobased Synthetic and Mineral Oil Emulsions in Machining Titanium Ti-6Al-4V at Low Cutting Speed. Journal of Manufacturing and material processing. 6 (6), pp. 1-16. https://doi.org/10.3390/jmmp6060154
Surface engineering of carbon fibre/epoxy composites with woven steel mesh for adhesion strength enhancement
Pawlik, M., Cheah, L.Y.Y, Gunputh, U., Le, H., Wood, P. and Lu, Y. 2022. Surface engineering of carbon fibre/epoxy composites with woven steel mesh for adhesion strength enhancement. International Journal of Adhesion and Adhesives. 114, pp. 1-8. https://doi.org/10.1016/j.ijadhadh.2022.103105
Managing Intellectual Property Issues with Digital Twins
Clementson, J., Wood, P. and Windmill, C. 2021. Managing Intellectual Property Issues with Digital Twins. INCOSEUK ASEC 2021. INCOSEUK.
Legal Considerations for Using Digital Twins in Additive Manufacture - A Review of the Literature
Clementson, J., Teng, J., Wood, P. and Windmill, C. 2021. Legal Considerations for Using Digital Twins in Additive Manufacture - A Review of the Literature. in: Shafik, M. and Case, K (ed.) Volume 15: Advances in Manufacturing Technology XXXIV Amsterdam IOS Press. pp. 91-96
Additive manufacturing of graded structures in IN718
Wood, Paul and Gunputh, Urvashi 2019. Additive manufacturing of graded structures in IN718.
Selective laser melting of a high precision turbomachinery application in IN718 alloy
Wood, Paul, Gunputh, Urvashi, Williams, Gavin, Carter, Wayne, Boud, Fathi, Bahi, Slim, Rusinek, Alexis, Kowalewski, Zbigniew, Nowak, Zdzisław, Libura, Tomasz, Voyiadjis, George, Diaz-Alvarez, Jose and Miguelez, María 2021. Selective laser melting of a high precision turbomachinery application in IN718 alloy.
Analysis of machining performance of Inconel 718 printed by PBF-LM (powder bed fusion laser melting)
Diaz-Alvarez, A, Diaz-Alvarez, J, Wood, P, Gunputh, U, Rusinek, A and Miguelez, M 2021. Analysis of machining performance of Inconel 718 printed by PBF-LM (powder bed fusion laser melting).
Selective laser melting of stainless steel 316L pressure fittings
Wood, Paul 2019. Selective laser melting of stainless steel 316L pressure fittings.
Analysis of parameters influencing build accuracy of a SLM printed compressor outlet guide vane
Otubusin, Adetayo, Wood, Paul, Appleby, John and Adamczuk, Rafael 2018. Analysis of parameters influencing build accuracy of a SLM printed compressor outlet guide vane. American Society of Mechanical Engineers. https://doi.org/10.1115/GT2018-75548
Effect of powder bed fusion laser melting process parameters, build orientation and strut thickness on porosity, accuracy and tensile properties of an auxetic structure in IN718 alloy
Bahi, S., Gunputh, U., Rusinek, A., Wood, P. and Miguelez, M.H. 2020. Effect of powder bed fusion laser melting process parameters, build orientation and strut thickness on porosity, accuracy and tensile properties of an auxetic structure in IN718 alloy. Additive Manufacturing. 36, p. 101339. https://doi.org/10.1016/j.addma.2020.101339
A review of in-situ grown nanocomposite coatings for titanium alloy implants
Gunputh, Urvashi Fowdar, Le, Huirong and Pawlik, Marzena 2020. A review of in-situ grown nanocomposite coatings for titanium alloy implants. Journal of Composites Science. 4 (2), p. 41. https://doi.org/10.3390/jcs4020041
Effect of element wall thickness on the homogeneity and isotropy of hardness in SLM IN718 using nanoindentation
Abo Znemah, Reem, Wood, Paul, Gunputh, Urvashi Fowdar and Zhang, Cheng 2020. Effect of element wall thickness on the homogeneity and isotropy of hardness in SLM IN718 using nanoindentation. Mechanics Research Communications. https://doi.org/10.1016/j.mechrescom.2020.103568
Influences of horizontal and vertical build orientations and post-fabrication processes on the fatigue behavior of stainless steel 316l produced by selective laser melting
Wood, Paul, Libura, Tomasz, Kowalewski, Zbigniew L., Williams, Gavin and Serjouei, Ahmad 2019. Influences of horizontal and vertical build orientations and post-fabrication processes on the fatigue behavior of stainless steel 316l produced by selective laser melting. Materials. 12 (24), p. 4203. https://doi.org/10.3390/ma12244203
A novel technique for dynamic shear testing of bulk metals with application to 304 austenitic stainless steel
Jia, B., Rusinek, A., Pesci, R., Bernier, R., Bahi, S. and Wood, P. 2020. A novel technique for dynamic shear testing of bulk metals with application to 304 austenitic stainless steel. International Journal of Solids and Structures. 204-205, pp. 153-171. https://doi.org/10.1016/j.ijsolstr.2020.08.019
Antibacterial properties of silver nanoparticles grown in situ and anchored to titanium dioxide nanotubes on titanium implant against Staphylococcus aureus
Gunputh, Urvashi Fowdar, Le, Huirong, Lawton, Kiruthika, Besinis, Alexandros, Tredwin, Christopher and Handy, Richard D. 2019. Antibacterial properties of silver nanoparticles grown in situ and anchored to titanium dioxide nanotubes on titanium implant against Staphylococcus aureus. Nanotoxicology. https://doi.org/10.1080/17435390.2019.1665727
Multilayered composite coatings of titanium dioxide nanotubes decorated with zinc oxide and hydroxyapatite nanoparticles: controlled release of Zn and antimicrobial properties against <em>Staphylococcus aureus</em></p>
Gunputh, Urvashi Fowdar, Le, Huirong, Besinis, Alexandros, Tredwin, Christopher and Handy, Richard 2019. Multilayered composite coatings of titanium dioxide nanotubes decorated with zinc oxide and hydroxyapatite nanoparticles: controlled release of Zn and antimicrobial properties against <em>Staphylococcus aureus</em></p>. International Journal of Nanomedicine. Volume 14, pp. 3583-3600. https://doi.org/10.2147/ijn.s199219
Design for plant modularisation: nuclear and SMR.
Wrigley, Paul, Wood, Paul, Stewart, Paul, Hall, Richard and Robertson, Dan 2018. Design for plant modularisation: nuclear and SMR. 2018 26th International Conference on Nuclear Engineering Conference Proceedings. https://doi.org/10.1115/ICONE26-81760
Module layout optimization using a genetic algorithm in light water modular nuclear reactor power plants.
Wrigley, P.A., Wood, Paul, Stewart, Paul, Hall, Richard and Robertson, D. 2018. Module layout optimization using a genetic algorithm in light water modular nuclear reactor power plants. Nuclear Engineering and Design. https://doi.org/10.1016/j.nucengdes.2018.10.023
Module layout optimization using a genetic algorithm in light water modular nuclear reactor power plants.
Wrigley, P.A., Wood, P., Stewart, Paul and Robertson, D. 2018. Module layout optimization using a genetic algorithm in light water modular nuclear reactor power plants. Nuclear Engineering and Design. https://doi.org/10.1016/j.nucengdes.2018.10.023
Anodised TiO 2 nanotubes as a scaffold for antibacterial silver nanoparticles on titanium implants.
Gunputh, Urvashi Fowdar, Le, Huirong, Handy, Richard and Tredwin, Christopher 2018. Anodised TiO 2 nanotubes as a scaffold for antibacterial silver nanoparticles on titanium implants. Materials Science and Engineering: C. https://doi.org/10.1016/j.msec.2018.05.074
Mechanical properties and microstructure of AZ31B magnesium alloy processed by I-ECAP.
Gzyl, Michal, Rosochowski, Andrzej, Pesci, Raphael, Olejnik, Lech, Yakushina, Evgenia and Wood, Paul 2013. Mechanical properties and microstructure of AZ31B magnesium alloy processed by I-ECAP. Metallurgical and Materials Transactions A. https://doi.org/10.1007/s11661-013-2094-z
An investigation into metal coated additively manufactured polymer lattice structures
Farhan Khan, Muhammad, Williams, Gavin and Maligno, Angelo 2016. An investigation into metal coated additively manufactured polymer lattice structures. OMICS International. https://doi.org/10.4172/2169-0022.C1.037