Advertisement

Electrical Discharge Machining Performance of Deep Cryogenically Treated Inconel 825 Superalloy: Emphasis on Surface Integrity

  • Rahul
  • Saurav DattaEmail author
Article
  • 24 Downloads

Abstract

Electrical discharge machining performance of deep cryogenically treated Inconel 825 superalloy was assessed and compared to that of normal workpiece. Machining performance was evaluated in purview of surface integrity which articulated studies on morphology and topography of the EDMed surface. Severity of surface cracking was found relatively less on the machined specimen of cryogenically treated workpiece (CTW) while comparing non-treated workpiece. Moreover, machined specimen of CTW exhibited formation of tiny white layer. Other topographical measures including material migration, surface residual stress, and micro-indentation hardness of the machined specimen were analyzed. Effects of cryogenic treatment of the workpiece followed by EDM operation were discussed emphasizing on metallurgical aspects of the machined surface. Moreover, effects of cooling rate set for the cryogenic treatment cycle were also investigated on influencing EDM performance of CTW.

Keywords

Electrical discharge machining Deep cryogenically treated Inconel 825 Surface cracking White layer Material migration Surface residual stress Micro-indentation hardness 

References

  1. 1.
    E.O. Ezugwu, Key improvements in the machining of difficult-to-cut aerospace superalloys. Int. J. Mach. Tools Manuf 45(12–13), 1353–1367 (2005)Google Scholar
  2. 2.
    I.A. Choudhury, M.A. El-Baradie, Machinability of nickel-base super alloys: a general review. J. Mater. Process. Technol. 77(1–3), 278–284 (1998)Google Scholar
  3. 3.
    G. Rajyalakshmi, P.V. Ramaiah, Multiple process parameter optimization of wire electrical discharge machining on Inconel 825 using Taguchi grey relational analysis. Int. J. Adv. Manuf. Technol. 69(5), 1249–1262 (2003)Google Scholar
  4. 4.
    T.R. Newton, S.N. Melkote, T.R. Watkins, R.M. Trejo, L. Reister, Investigation of the effect of process parameters on the formation and characteristics of recast layer in wire-EDM of Inconel 718. Mater. Sci. Eng. A 513–514, 208–215 (2009)Google Scholar
  5. 5.
    M. Ay, U. Çaydaş, A. Hasçalık, Optimization of micro-EDM drilling of Inconel 718 super alloy. Int. J. Adv. Manuf. Technol. 66(5), 1015–1023 (2013)Google Scholar
  6. 6.
    M.Y. Lin, C.C. Tsao, C.Y. Hsu, A.H. Chiou, P.C. Huang, Y.C. Lin, Optimization of micro milling electrical discharge machining of Inconel 718 by Grey–Taguchi method. Trans. Nonferrous Metals Soc. China 23(3), 661–666 (2013)Google Scholar
  7. 7.
    S. Dhanabalan, K. Sivakumar, C.S. Narayanan, Analysis of form tolerances in electrical discharge machining process for Inconel 718 and 625. Mater. Manuf. Process. 29(3), 253–259 (2014)Google Scholar
  8. 8.
    V. Agarwal, S.S. Khangura, R.K. Garg, Parametric modeling and optimization for wire electrical discharge machining of Inconel 718 using response surface methodology. Int. J. Adv. Manuf. Technol. 79(1–4), 31–47 (2015)Google Scholar
  9. 9.
    L. Li, Z.Y. Li, X.T. Wei, X. Cheng, Machining characteristics of Inconel 718 by sinking-EDM and wire-EDM. Mater. Manuf. Process. 30(8), 968–973 (2015)Google Scholar
  10. 10.
    Z. Chen, J. Moverare, R.L. Peng, S. Johansson, Surface integrity and fatigue performance of Inconel 718 in wire electrical discharge machining. Procedia CIRP 45, 307–310 (2016)Google Scholar
  11. 11.
    C.B. Yang, C.G. Lin, H.L. Chiang, C.C. Chen, Single and multi-objective optimization of Inconel 718 nickel-based superalloy in the wire electrical discharge machining. Int. J. Adv. Manuf. Technol. 93(9–12), 3075–3084 (2017)Google Scholar
  12. 12.
    J. Holmberg, A. Wretland, J. Berglund, T. Beno, Surface integrity after post processing of EDM processed Inconel 718 shaft. Int. J. Adv. Manuf. Technol. (2017).  https://doi.org/10.1007/s00170-017-1342-6 Google Scholar
  13. 13.
    Y. Shen, Y. Liu, H. Dong, K. Zhang, L. Lv, X. Zhang, X. Wu, C. Zheng, R. Ji, Surface integrity of Inconel 718 in high-speed electrical discharge machining milling using air dielectric. Int. J. Adv. Manuf. Technol. 90(1–4), 691–698 (2017)Google Scholar
  14. 14.
    D. Das, A.K. Dutta, K.K. Ray, On the enhancement of wear resistance of tool steels by cryogenic treatment. J. Philos. Mag. Lett. 88(11), 801–811 (2008)Google Scholar
  15. 15.
    S. Kumar, A. Batish, R. Singh, T.P. Sing, A hybrid Taguchi artificial neural network approach to predict surface roughness during electric discharge machining of titanium alloys. J. Mech. Sci. Technol. 28(7), 2831–2844 (2014)Google Scholar
  16. 16.
    S. Kumar, R. Singh, A. Batish, T.P. Singh, Modeling the tool wear rate in powder mixed electro-discharge machining of titanium alloys using dimensional analysis of cryogenically treated electrodes and workpiece. Proc. Inst. Mech. Eng. Part E J. Process Mech. Eng. 231, 271–282 (2015)Google Scholar
  17. 17.
    S.S. Gill, J. Singh, Effect of deep cryogenic treatment on machinability of titanium alloy (Ti-6246) in electric discharge drilling. Mater. Manuf. Process. 25(6), 378–385 (2010)Google Scholar
  18. 18.
    N.S. Kalsi, R. Sehgal, V.S. Sharma, Cryogenic treatment of tool materials: a review. Mater. Manuf. Process. 25(10), 1077–1100 (2010)Google Scholar
  19. 19.
    M.M. Sundaram, Y. Yildiz, K.P. Rajurkar, Experimental study of the effect of cryogenic treatment on the performance of electro-discharge machining, in International Manufacturing Science and Engineering Conference (American Society of Mechanical Engineers, 2009), pp. 215–222Google Scholar
  20. 20.
    S. Abdulkareem, A.A. Khan, M. Konneh, Reducing electrode wear ratio using cryogenic cooling during electrical discharge machining. Int. J. Adv. Manuf. Technol. 45(11–12), 1146–1151 (2009)Google Scholar
  21. 21.
    D.S. Nadig, V. Ramakrishnan, P. Sampathkumaran, C.S. Prashanth, Effect of cryogenic treatment on thermal conductivity properties of copper. AIP Conf. Proc. 1435(1), 133–139 (2012)Google Scholar
  22. 22.
    A. Bensely, A. Prabhakaran, D.M. Lal, G. Nagarajan, Enhancing the wear resistance of case carburized steel (En 353) by cryogenic treatment. Cryogenics 45(12), 747–754 (2006)Google Scholar
  23. 23.
    D. Das, A.K. Dutta, V. Toppo, K.K. Ray, Effect of deep cryogenic treatment on the carbide precipitation and tribological behavior of D2 Steel. Mater. Manuf. Process. 22(4), 474–480 (2007)Google Scholar
  24. 24.
    A. Akhbarizadeh, A. Shafyei, M.A. Golozar, Effects of cryogenic treatment on wear behavior of D6 tool steel. Mater. Des. 30(8), 3259–3264 (2009)Google Scholar
  25. 25.
    R. Khanna, H. Singh, Comparison of optimized settings for cryogenic-treated and normal D-3 steel on WEDM using grey relational theory. Proc. Inst. Mech. Eng. Part L J. Mater. Des. Appl. 230, 219–232 (2014)Google Scholar
  26. 26.
    S. Kumar, R. Singh, A. Batish, T.P. Singh, R. Singh, Investigating surface properties of cryogenically treated titanium alloys in powder mixed electric discharge machining. J. Braz. Soc. Mech. Sci. Eng. (2016).  https://doi.org/10.1007/s40430-016-0639-y Google Scholar
  27. 27.
    S. Kumar, A. Batish, R. Singh, A. Bhattacharya, Effect of cryogenically treated copper-tungsten electrode on tool wear rate during electro-discharge machining of Ti–5Al–2.5Sn alloy. Wear 386–387, 223–229 (2017)Google Scholar
  28. 28.
    Rahul, D.K. Mishra, S. Datta, M. Masanta, Effects of tool electrode on EDM performance of Ti–6Al–4V. Silicon 10(5), 2263–2277 (2018)Google Scholar
  29. 29.
    S. Prabhu, B.K. Vinayagam, AFM surface investigation of Inconel 825 with multi wall carbon nano tube in electrical discharge machining process using Taguchi analysis. Arch. Civ. Mech. Eng. 11(1), 149–169 (2011)Google Scholar
  30. 30.
    B.D. Cullity, Elements of X-ray Diffraction, 2nd edn. (Addison Wesley, Boston, 1978), p. 470Google Scholar
  31. 31.
    C.J. Isaak, W. Reitz, The effects of cryogenic treatment on the thermal conductivity of GRCop-84. Mater. Manuf. Process. 23(1), 82–91 (2008)Google Scholar
  32. 32.
    M. Merklein, K. Andreas, U. Engel, Influence of machining process on residual stresses in the surface of cemented carbides. Proceedia Eng. 19, 252–257 (2011)Google Scholar
  33. 33.
    Datta S. Rahul, B.B. Biswal, S.S. Mahapatra, Electrical discharge machining of Inconel 825 using cryogenically treated copper electrode: emphasis on surface integrity and metallurgical characteristics. J. Manuf. Process. 26, 188–202 (2017)Google Scholar
  34. 34.
    Y.P.V. Subbaiah, P. Prathap, K.T.P. Reddy, Structural, electrical and optical properties of ZnS films deposited by close-spaced evaporation. Appl. Surf. Sci. 253(5), 2409–2415 (2006)Google Scholar
  35. 35.
    P. Singh, A. Kumar, A. Kaushal, D. Kaur, A. Pandey, R.N. Goyal, In situ high temperature XRD studies of ZnO nanopowder prepared via cost effective ultrasonic mist chemical vapour deposition. Bull. Mater. Sci. 31(3), 573–577 (2008)Google Scholar
  36. 36.
    V.S. Vinila, R. Jacob, A. Mony, H.G. Nair, S. Issac, S. Rajan, A.S. Nair, J. Isac, XRD studies on nano crystalline ceramic superconductor PbSrCaCuO at different treating temperatures. Cryst. Struct. Theory Appl. 3(1), 1–9 (2014)Google Scholar
  37. 37.
    R. Jacob, H.G. Nair, J. Isac, Structural and morphological studies of nanocrystalline ceramic BaSr0.9Fe0.1TiO4. Int. Lett. Chem. Phys. Astron. 41, 100–117 (2015)Google Scholar

Copyright information

© ASM International 2019

Authors and Affiliations

  1. 1.School of Mechanical SciencesKalinga Institute of Industrial TechnologyBhubaneswarIndia
  2. 2.Department of Mechanical EngineeringNational Institute of TechnologyRourkelaIndia

Personalised recommendations