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<p>Additive manufacturing (AM), more commonly known as three-dimensional printing (3D printing), has become an important process for manufacturing complex aerospace components made of Inconel alloys. The objective of this study is to investigate the machinability characteristics of additively manufactured Inconel 718 alloy against the traditional wrought Inconel 718 alloy. The machinability of laser powder bed fusion (LPBF) printed Inconel 718 alloy has been compared with that of wrought Inconel 718 parts in terms of important performance measures, such as, cutting forces, tool temperature, tool wear, and surface finish. The machining experiments were carried out in dry, flood coolant, and minimum quantity lubrication (MQL) conditions using both uncoated and titanium-aluminum-nitride (TiAlN) coated tungsten carbide (WC) cutting tools. It was found from the experimental results that additively manufactured Inconel 718 alloy exhibited lower cutting force, lower tool temperature, lesser tool breakage, and a lower surface roughness on the machined slots compared to those of traditional wrought Inconel 718 alloy. The uncoated carbide tools performed better in terms of providing comparatively lower cutting force, lower tool temperature, lower average surface roughness (Ra), and lower peak-to-valley surface roughness (Rz) compared to their counterpart TiAlN coated tools. The effectiveness of TiAlN coating was not noticeable when machining additively manufactured Inconel alloy. It was found that both TiAlN coated and uncoated carbide tools suffered the same number of tool breakage while machining similar number of slots on 3D printed and traditional Inconel alloys. When investigating potential reasons for difference in machinability, it was found that the material composition of 3D printed and traditional Inconel alloys differed, as confirmed by the energy dispersive X-ray spectroscopy (EDS) analysis. It was also found that 3D printed Inconel alloy had inconsistent surface hardness possibly resulting from the splatter during the LPBF process. In addition, the porosity associated with the 3D printing process also contributes to comparatively lower cutting forces and tool temperatures during machining. Overall, the LPBF printed Inconel alloy exhibited comparatively better machinability than traditional wrought Inconel alloy part, irrespective of the cooling/lubricating conditions.</p>

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A comparative experimental study on the machinability of 3D printed and wrought inconel 718 alloys in dry, MQL, and flood coolant conditions

  • 期刊论文

  • 发表日期：

    2026年3月16日

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  • Noah Lambert,
  • Mahmud Anjir Karim,
  • Kaden McNear,
  • Clay Witt,
  • Dj Muncy,
  • Tyler Finley,
  • Greg Arbuckle,
  • Bryan Reaka,
  • Ahsan Mian,
  • Muhammad Pervej Jahan

摘要

Additive manufacturing (AM), more commonly known as three-dimensional printing (3D printing), has become an important process for manufacturing complex aerospace components made of Inconel alloys. The objective of this study is to investigate the machinability characteristics of additively manufactured Inconel 718 alloy against the traditional wrought Inconel 718 alloy. The machinability of laser powder bed fusion (LPBF) printed Inconel 718 alloy has been compared with that of wrought Inconel 718 parts in terms of important performance measures, such as, cutting forces, tool temperature, tool wear, and surface finish. The machining experiments were carried out in dry, flood coolant, and minimum quantity lubrication (MQL) conditions using both uncoated and titanium-aluminum-nitride (TiAlN) coated tungsten carbide (WC) cutting tools. It was found from the experimental results that additively manufactured Inconel 718 alloy exhibited lower cutting force, lower tool temperature, lesser tool breakage, and a lower surface roughness on the machined slots compared to those of traditional wrought Inconel 718 alloy. The uncoated carbide tools performed better in terms of providing comparatively lower cutting force, lower tool temperature, lower average surface roughness (Ra), and lower peak-to-valley surface roughness (Rz) compared to their counterpart TiAlN coated tools. The effectiveness of TiAlN coating was not noticeable when machining additively manufactured Inconel alloy. It was found that both TiAlN coated and uncoated carbide tools suffered the same number of tool breakage while machining similar number of slots on 3D printed and traditional Inconel alloys. When investigating potential reasons for difference in machinability, it was found that the material composition of 3D printed and traditional Inconel alloys differed, as confirmed by the energy dispersive X-ray spectroscopy (EDS) analysis. It was also found that 3D printed Inconel alloy had inconsistent surface hardness possibly resulting from the splatter during the LPBF process. In addition, the porosity associated with the 3D printing process also contributes to comparatively lower cutting forces and tool temperatures during machining. Overall, the LPBF printed Inconel alloy exhibited comparatively better machinability than traditional wrought Inconel alloy part, irrespective of the cooling/lubricating conditions.