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Machining of additively manufactured alloy 718 in as-built and heat-treated condition: surface integrity and cutting tool wear
RISE Research Institutes of Sweden, Materials and Production, Manufacturing Processes.ORCID iD: 0000-0003-2991-2911
RISE Research Institutes of Sweden, Materials and Production, Manufacturing Processes.ORCID iD: 0000-0003-3656-1806
Swerim AB, Sweden.
Luleå university of Technolgy, Sweden.
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2023 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 130, no 3-4, p. 1823-1842Article in journal (Refereed) Published
Abstract [en]

Additive manufacturing (AM) using powder bed fusion is becoming a mature technology that offers great possibilities and design freedom for manufacturing of near net shape components. However, for many gas turbine and aerospace applications, machining is still required, which motivates further research on the machinability and work piece integrity of additive-manufactured superalloys. In this work, turning tests have been performed on components made with both Powder Bed Fusion for Laser Beam (PBF-LB) and Electron Beam (PBF-EB) in as-built and heat-treated conditions. The two AM processes and the respective heat-treatments have generated different microstructural features that have a great impact on both the tool wear and the work piece surface integrity. The results show that the PBF-EB components have relatively lower geometrical accuracy, a rough surface topography, a coarse microstructure with hard precipitates and low residual stresses after printing. Turning of the PBF-EB material results in high cutting tool wear, which induces moderate tensile surface stresses that are balanced by deep compressive stresses and a superficial deformed surface that is greater for the heat-treated material. In comparison, the PBF-LB components have a higher geometrical accuracy, a relatively smooth topography and a fine microstructure, but with high tensile stresses after printing. Machining of PBF-LB material resulted in higher tool wear for the heat-treated material, increase of 49%, and significantly higher tensile surface stresses followed by shallower compressive stresses below the surface compared to the PBF-EB materials, but with no superficially deformed surface. It is further observed an 87% higher tool wear for PBF-EB in as-built condition and 43% in the heat-treated condition compared to the PBF-LB material. These results show that the selection of cutting tools and cutting settings are critical, which requires the development of suitable machining parameters that are designed for the microstructure of the material.

Place, publisher, year, edition, pages
Springer Science and Business Media Deutschland GmbH , 2023. Vol. 130, no 3-4, p. 1823-1842
Keywords [en]
3D printing; Additives; Aerospace applications; Compressive stress; Cutting tools; Microstructure; Surface stress; Topography; Turning; Wear of materials; Alloy 718; Beam components; Beam material; Electron-beam; Geometrical accuracy; Heat treated condition; Powder bed; Surface integrity; Tensile surface stress; Tool wear; Laser beams
National Category
Manufacturing, Surface and Joining Technology
Identifiers
URN: urn:nbn:se:ri:diva-68829DOI: 10.1007/s00170-023-12727-wScopus ID: 2-s2.0-85179663025OAI: oai:DiVA.org:ri-68829DiVA, id: diva2:1824867
Funder
Vinnova, 2016–05175Swedish Foundation for Strategic Research, GMT14-048Swedish Research Council, 2016–05460
Note

Open access funding provided by RISE Research Institutes of Sweden. This research has been funded by the Swedish Arena for Additive Manufacturing and Vinnova through grant ref no. 2016–05175. The researchers at Uppsala acknowledge the Swedish Foundation for Strategic Research (SSF) project GMT14-048 (Additive Manufacturing—Development of Process and Materials) and the Swedish Research Council, grant 2016–05460, for financial support.

Available from: 2024-01-08 Created: 2024-01-08 Last updated: 2024-01-08Bibliographically approved

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Holmberg, JonasBerglund, JohanHosseini, Seyed

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