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<p>Superalloys, owing to their superior mechanical properties and remarkable high-temperature resistance, are extensively utilized in hot-end components of aero engines, gas turbine blades, and other critical parts. The development of efficient and precise processing technologies for these materials is intrinsically linked to the operational performance and lifecycle of major equipment, thereby playing a crucial role in the aerospace industry and related fields. Nevertheless, their significant hardness and poor thermal conductivity create substantial difficulties for conventional machining techniques. Ultrasonic vibration-assisted milling (UVAM) incorporates high-frequency ultrasonic vibrations (HFUV) to intermittently separate the tool from the workpiece. This action significantly diminishes milling forces and temperatures, leading to reduced tool wear, superior surface finish, and increased machining efficiency. This review conducts a comprehensive investigation into UVAM’ influence on the surface integrity of superalloys from multiple perspectives, encompassing aspects such as surface morphology, roughness, subsurface microstructure, surface hardness, and residual stress distribution. Drawing on existing research outcomes, this review outlines possible avenues for future investigation and addresses the associated technical hurdles, laying a solid theoretical groundwork for further exploration.</p>

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Surface integrity of superalloys during ultrasonic vibration-assisted milling processes: research status and challenges

  • 期刊论文

  • 发表日期：

    2025年6月18日

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  • Qingliao He,
  • Xin Wang,
  • Shaorong Ma,
  • Zhengping Li,
  • Carlos Eiji Hirata Ventura,
  • Biao Zhao,
  • Wenfeng Ding

摘要

Superalloys, owing to their superior mechanical properties and remarkable high-temperature resistance, are extensively utilized in hot-end components of aero engines, gas turbine blades, and other critical parts. The development of efficient and precise processing technologies for these materials is intrinsically linked to the operational performance and lifecycle of major equipment, thereby playing a crucial role in the aerospace industry and related fields. Nevertheless, their significant hardness and poor thermal conductivity create substantial difficulties for conventional machining techniques. Ultrasonic vibration-assisted milling (UVAM) incorporates high-frequency ultrasonic vibrations (HFUV) to intermittently separate the tool from the workpiece. This action significantly diminishes milling forces and temperatures, leading to reduced tool wear, superior surface finish, and increased machining efficiency. This review conducts a comprehensive investigation into UVAM’ influence on the surface integrity of superalloys from multiple perspectives, encompassing aspects such as surface morphology, roughness, subsurface microstructure, surface hardness, and residual stress distribution. Drawing on existing research outcomes, this review outlines possible avenues for future investigation and addresses the associated technical hurdles, laying a solid theoretical groundwork for further exploration.