Impact of morphological and mechanical components on inconel 625 grinding using common cylindrical grinding wheels
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Jul 25, 2024
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Abstract
This study used a grinding technique based on Gas Tungsten Arc Welding (GTAW) to create walls composed of Inconel 625 alloy. Mechanical and microstructural (MM) adjustments are structural and mechanical alterations that take place during the additive manufacturing process of Inconel 625 grinding. A thorough examination of the modifications made to the nickel superalloy Inconel 625's (I-625) microstructure was conducted during the grinding process. A circular weave and a stringer bead design were used to construct the wall. Tensile properties and microstructural analyses were assessed for each wall. Using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS), the fracture zones of the tensile specimens were examined. The microstructure is mostly composed of equiaxed dendrites, although a unique combination of discontinuous and continuous cellular dendrites can be observed along the cross-section. In tensile testing, circular woven walls performed better than stringer bead walls. The EDS and AFM results show that Ni and Cr make up the majority of the fracture zone, with traces of Nb and Mo. Because there are no lave phases, the fracture mode is ductile. The elemental mapping, which shows the homogenous dispersion of Ni and Cr inside the fracture zone, provides additional evidence in favor of the ductile failure mode. The UTS of the time-consuming TS samples is somewhat higher and exhibits a steadily rising bias in comparison to the specimens with quick TS. The highest level of the UTS sample is 10 %.
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References
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[23] M. S. de Lorenzi, R. M. Nunes, T. Falcade, and T. Clarke, “Evaluation of the Influence of Surface Finishing on the Corrosion Resistance of HVOF Applied Inconel 625 Coatings on Steel,” Materials Research, vol. 21, no. 2, Dec. 2017, doi: 10.1590/1980-5373-mr-2016-0844.
[24] D. Lipiński, W. Kacalak, and B. Bałasz, “Optimization of sequential grinding process in a fuzzy environment using genetic algorithms,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 41, no. 2, p. 96, Feb. 2019, doi: 10.1007/s40430-019-1601-6.
[25] M. Rezapoor, M. Razavi, M. Zakeri, M. R. Rahimipour, and L. Nikzad, “Fabrication of functionally graded Fe-TiC wear resistant coating on CK45 steel substrate by plasma spray and evaluation of mechanical properties,” Ceramics International, vol. 44, no. 18, pp. 22378–22386, Dec. 2018, doi: 10.1016/j.ceramint.2018.09.001.
[26] D. Bandhu, A. Thakur, R. Purohit, R. K. Verma, and K. Abhishek, “Characterization & evaluation of Al7075 MMCs reinforced with ceramic particulates and influence of age hardening on their tensile behavior,” Journal of Mechanical Science and Technology, vol. 32, no. 7, pp. 3123–3128, Jul. 2018, doi: 10.1007/s12206-018-0615-9.
[27] S. V. Wagh et al., “Effects of low-power laser hardening on the mechanical and metallurgical properties of biocompatible SAE 420 steel,” Journal of Materials Research and Technology, vol. 30, pp. 1611–1619, May 2024, doi: 10.1016/j.jmrt.2024.03.153.
[2] A. Chintala, M. Tejaswi Kumar, M. Sathishkumar, N. Arivazhagan, and M. Manikandan, “Technology Development for Producing Inconel 625 in Aerospace Application Using Wire Arc Additive Manufacturing Process,” Journal of Materials Engineering and Performance, vol. 30, no. 7, pp. 5333–5341, Jul. 2021, doi: 10.1007/s11665-021-05781-6.
[3] A. Safarzade, M. Sharifitabar, and M. Shafiee Afarani, “Effects of heat treatment on microstructure and mechanical properties of Inconel 625 alloy fabricated by wire arc additive manufacturing process,” Transactions of Nonferrous Metals Society of China, vol. 30, no. 11, pp. 3016–3030, Nov. 2020, doi: 10.1016/S1003-6326(20)65439-5.
[4] Y. Wang et al., “Effect of magnetic Field on the microstructure and mechanical properties of inconel 625 superalloy fabricated by wire arc additive manufacturing,” Journal of Manufacturing Processes, vol. 64, pp. 10–19, Apr. 2021, doi: 10.1016/j.jmapro.2021.01.008.
[5] M. Cheepu, C. I. Lee, and S. M. Cho, “Microstructural Characteristics of Wire Arc Additive Manufacturing with Inconel 625 by Super-TIG Welding,” Transactions of the Indian Institute of Metals, vol. 73, no. 6, pp. 1475–1479, Jun. 2020, doi: 10.1007/s12666-020-01915-x.
[6] D. Sarathchandra and M. Davidson, “Effect of heat input on mechanical and microstructural properties of Inconel 625 depositions processed in wire arc additive manufacturing,” Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, vol. 235, no. 5, pp. 1439–1448, Oct. 2021, doi: 10.1177/09544089211004718.
[7] G. Ravi, N. Murugan, and R. Arulmani, “Microstructure and mechanical properties of Inconel-625 slab component fabricated by wire arc additive manufacturing,” Materials Science and Technology, vol. 36, no. 16, pp. 1785–1795, Nov. 2020, doi: 10.1080/02670836.2020.1836737.
[8] S. Mohan Kumar et al., “Microstructural Features and Mechanical Integrity of Wire Arc Additive Manufactured SS321/Inconel 625 Functionally Gradient Material,” Journal of Materials Engineering and Performance, vol. 30, no. 8, pp. 5692–5703, Aug. 2021, doi: 10.1007/s11665-021-05617-3.
[9] M. Karmuhilan and S. Kumanan, “A Review on Additive Manufacturing Processes of Inconel 625,” Journal of Materials Engineering and Performance, vol. 31, no. 4, pp. 2583–2592, Apr. 2022, doi: 10.1007/s11665-021-06427-3.
[10] M. Sharifitabar, S. Khorshahian, M. Shafiee Afarani, P. Kumar, and N. K. Jain, “High-temperature oxidation performance of Inconel 625 superalloy fabricated by wire arc additive manufacturing,” Corrosion Science, vol. 197, p. 110087, Apr. 2022, doi: 10.1016/j.corsci.2022.110087.
[11] C. Zhang et al., “On the Effect of Heat Input and Interpass Temperature on the Performance of Inconel 625 Alloy Deposited Using Wire Arc Additive Manufacturing–Cold Metal Transfer Process,” Metals, vol. 12, no. 1, p. 46, Dec. 2021, doi: 10.3390/met12010046.
[12] T. A. Rodrigues et al., “Wire and arc additive manufacturing of 316L stainless steel/Inconel 625 functionally graded material: development and characterization,” Journal of Materials Research and Technology, vol. 21, pp. 237–251, Nov. 2022, doi: 10.1016/j.jmrt.2022.08.169.
[13] I. Jurić, I. Garašić, M. Bušić, and Z. Kožuh, “Influence of Shielding Gas Composition on Structure and Mechanical Properties of Wire and Arc Additive Manufactured Inconel 625,” JOM, vol. 71, no. 2, pp. 703–708, Feb. 2019, doi: 10.1007/s11837-018-3151-2.
[14] A. Gamon et al., “Microstructure and hardness comparison of as-built inconel 625 alloy following various additive manufacturing processes,” Results in Materials, vol. 12, p. 100239, Dec. 2021, doi: 10.1016/j.rinma.2021.100239.
[15] V. Votruba et al., “Experimental investigation of CMT discontinuous wire arc additive manufacturing of Inconel 625,” The International Journal of Advanced Manufacturing Technology, vol. 122, no. 2, pp. 711–727, Sep. 2022, doi: 10.1007/s00170-022-09878-7.
[16] K. Kishore, M. K. Sinha, and S. R. Chauhan, “A comprehensive investigation of surface morphology during grinding of Inconel 625 using conventional grinding wheels,” Journal of Manufacturing Processes, vol. 97, pp. 87–99, Jul. 2023, doi: 10.1016/j.jmapro.2023.04.053.
[17] S. N. Gupta and S. K. Chak, “Grinding temperature and its consequences on induced residual stresses during grinding of nickel-based superalloys: a review,” Engineering Research Express, vol. 4, no. 4, p. 042002, Dec. 2022, doi: 10.1088/2631-8695/acaa1d.
[18] K. Kishore, S. R. Chauhan, and M. K. Sinha, “Application of machine learning techniques in environmentally benign surface grinding of Inconel 625,” Tribology International, vol. 188, p. 108812, Oct. 2023, doi: 10.1016/j.triboint.2023.108812.
[19] L. Li et al., “Mechanical behavior and modeling of grinding force: A comparative analysis,” Journal of Manufacturing Processes, vol. 102, pp. 921–954, Sep. 2023, doi: 10.1016/j.jmapro.2023.07.074.
[20] A. F. V. Pedroso et al., “A Comprehensive Review on the Conventional and Non-Conventional Machining and Tool-Wear Mechanisms of INCONEL®,” Metals, vol. 13, no. 3, p. 585, Mar. 2023, doi: 10.3390/met13030585.
[21] Z. Li, W.-F. Ding, C.-Y. Ma, and J.-H. Xu, “Grinding temperature and wheel wear of porous metal-bonded cubic boron nitride superabrasive wheels in high-efficiency deep grinding,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 231, no. 11, pp. 1961–1971, Sep. 2017, doi: 10.1177/0954405415617928.
[22] H. González, O. Pereira, A. Fernández-Valdivielso, L. López de Lacalle, and A. Calleja, “Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces,” Materials, vol. 11, no. 9, p. 1638, Sep. 2018, doi: 10.3390/ma11091638.
[23] M. S. de Lorenzi, R. M. Nunes, T. Falcade, and T. Clarke, “Evaluation of the Influence of Surface Finishing on the Corrosion Resistance of HVOF Applied Inconel 625 Coatings on Steel,” Materials Research, vol. 21, no. 2, Dec. 2017, doi: 10.1590/1980-5373-mr-2016-0844.
[24] D. Lipiński, W. Kacalak, and B. Bałasz, “Optimization of sequential grinding process in a fuzzy environment using genetic algorithms,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 41, no. 2, p. 96, Feb. 2019, doi: 10.1007/s40430-019-1601-6.
[25] M. Rezapoor, M. Razavi, M. Zakeri, M. R. Rahimipour, and L. Nikzad, “Fabrication of functionally graded Fe-TiC wear resistant coating on CK45 steel substrate by plasma spray and evaluation of mechanical properties,” Ceramics International, vol. 44, no. 18, pp. 22378–22386, Dec. 2018, doi: 10.1016/j.ceramint.2018.09.001.
[26] D. Bandhu, A. Thakur, R. Purohit, R. K. Verma, and K. Abhishek, “Characterization & evaluation of Al7075 MMCs reinforced with ceramic particulates and influence of age hardening on their tensile behavior,” Journal of Mechanical Science and Technology, vol. 32, no. 7, pp. 3123–3128, Jul. 2018, doi: 10.1007/s12206-018-0615-9.
[27] S. V. Wagh et al., “Effects of low-power laser hardening on the mechanical and metallurgical properties of biocompatible SAE 420 steel,” Journal of Materials Research and Technology, vol. 30, pp. 1611–1619, May 2024, doi: 10.1016/j.jmrt.2024.03.153.