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Evaluation of surface integrity after high energy machining with EDM, laser beam machining and abrasive water jet machining of alloy 718
RISE - Research Institutes of Sweden, Materials and Production, IVF.ORCID iD: 0000-0003-2991-2911
RISE - Research Institutes of Sweden, Materials and Production, IVF.ORCID iD: 0000-0003-3656-1806
GKN Aerospace Sweden AB, Sweden.
University West, Sweden.
2019 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 100, no 5-8, p. 1575-1591Article in journal (Refereed) Published
Abstract [en]

Development of future aero engine components based on new design strategies utilising topological optimisation and additive manufacturing has in the past years become a reality. This allows for designs that involve geometries of “free form” surfaces and material combinations that could be difficult to machine using conventional milling. Hence, alternative manufacturing routes using non-conventional high energy methods are interesting to explore. In this investigation, the three high energy machining methods abrasive water jet machining (AWJM), electrical discharge machining (EDM) and laser beam machining (LBM) have been compared in terms of surface integrity to the reference, a ball nosed end milled surface. The results showed great influence on the surface integrity from the different machining methods. It was concluded that AWJM resulted in the highest quality regarding surface integrity properties with compressive residual stresses in the surface region and a low surface roughness with texture from the abrasive erosion. Further, it was shown that EDM resulted in shallow tensile residual stresses in the surface and an isotropic surface texture with higher surface roughness. However, even though both methods could be considered as possible alternatives to conventional milling they require post processing. The reason is that the surfaces need to be cleaned from either abrasive medium from AWJM or recast layer from EDM. It was further concluded that LBM should not be considered as an alternative in this case due to the deep detrimental impact from the machining process. © 2018, The Author(s).

Place, publisher, year, edition, pages
Springer London , 2019. Vol. 100, no 5-8, p. 1575-1591
Keywords [en]
Abrasives; Aircraft engines; Electric discharge machining; Electric discharges; Jets; Laser beams; Manufacture; Milling (machining); Residual stresses; Surface roughness; Topography, Abrasive water jet machining; Aero-engine components; Compressive residual stress; EBSD; Electrical discharge machining; Nonconventional machining; Surface integrity; Tensile residual stress, Laser beam machining
National Category
Metallurgy and Metallic Materials
Identifiers
URN: urn:nbn:se:ri:diva-35528DOI: 10.1007/s00170-018-2697-zScopus ID: 2-s2.0-85054583255OAI: oai:DiVA.org:ri-35528DiVA, id: diva2:1259559
Available from: 2018-10-30 Created: 2018-10-30 Last updated: 2019-06-28Bibliographically approved

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Holmberg, JonasBerglund, Johan

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