Machining behavior of additively manufactured and cast-wrought nickel-based super alloy (IN625)

Published

June 22, 2018

Author(s)

Rajesh K. Ananda-Kumar, Wilfredo Moscoso-Kingsley, Gregor Jacob, Alkan Donmez, Viswanathan Madhavan

Abstract

Additively manufactured (AM) and cast-wrought (CW) nickel-based super alloy (IN 625) with known processing history and quasi-static properties have been investigated for their relative machinability, in terms of tool temperature and wear, as well as force and chip morphology. The machining forces along the cutting and thrust directions were measured in situ using a piezoelectric-based dynamometer. The temperature field at the chip-tool interface was measured using near-infrared thermography, after direct interface observation using an intensified charge coupled device camera connected to a size-of-source-limiting lens. The tool wear and chip morphology were characterized post mortem by measurement of tool volume loss and by scanning the chip upper side, using a 3D profilometer. It was found that during machining, AM IN 625 behaves differently from CW IN 625 of similar composition. Significant differences in chip formation mechanisms, and tool temperature and wear were observed. The findings point in the direction in which future research should be conducted to optimize the hybrid AM + machining process, to produce net shape parts that are dimensionally accurate, and have highly integral surfaces.

Proceedings Title

Proceedings of the 46th SME North American Manufacturing Research Conference

Conference Dates

June 18-22, 2018

Conference Location

College Station, TX, US

Conference Title

46th SME North American Manufacturing Research Conference

Pub Type

Conferences

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Keywords

hybrid, additive, subtractive, machinability, temperature, wear

Citation

Ananda-Kumar, R. , Moscoso-Kingsley, W. , Jacob, G. , Donmez, A. and Madhavan, V. (2018), Machining behavior of additively manufactured and cast-wrought nickel-based super alloy (IN625), Proceedings of the 46th SME North American Manufacturing Research Conference, College Station, TX, US, [online], https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=925531 (Accessed October 25, 2025)