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<p>Additive manufactured (AM) offers significant design freedom for aerospace components, but many AM surfaces require machining to meet functional and dimensional requirements. Alloy 718 remains challenging to machine due to its high hot-hardness and strong work-hardening behaviour, and recent studies suggest that AM-induced microstructural variations may further influence machinability. This work compares the machinability with two solid end mill concepts, a cemented carbide tool and a binderless CBN (BL-CBN) tool, when machining Alloy 718 produced by Laser Powder Bed Fusion (PBF-LB) in three material conditions: As-built, Hot Isostatic Pressed (HIP), heat-treated (AMS 5662) using a wrought Alloy 718 as reference. The comparison focuses on tool wear and surface integrity, including surface topography, residual stresses, and near-surface deformation. Machining tests were performed on small blade-shaped samples representative of a thin-walled aerospace component geometry. The results show clear differences in machinability between the two tool concepts. The cemented carbide tool is highly sensitive to the material condition, leading to higher surface roughness and lower compressive residual stresses compared to the BL-CBN tool. In contrast, the BL-CBN tool provides stable performance across all AM conditions. For the relatively short cutting lengths studied, machining-induced deformation remained low for both tools in the AM materials. However, wrought Alloy 718 material remains the most challenging material to machine, as it caused highest tool wear, deepest residual stresses and largest plastic deformation.</p>

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Machinability and surface integrity evaluation of additive manufactured alloy 718 (PBF-LB) using binderless CBN and cemented carbide endmills

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月3日

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  • Jonas Holmberg,
  • Hirtsugu Iwasaki,
  • Shuhei Misumi,
  • Johan Fast Berglund,
  • Seyed Hosseini

摘要

Additive manufactured (AM) offers significant design freedom for aerospace components, but many AM surfaces require machining to meet functional and dimensional requirements. Alloy 718 remains challenging to machine due to its high hot-hardness and strong work-hardening behaviour, and recent studies suggest that AM-induced microstructural variations may further influence machinability. This work compares the machinability with two solid end mill concepts, a cemented carbide tool and a binderless CBN (BL-CBN) tool, when machining Alloy 718 produced by Laser Powder Bed Fusion (PBF-LB) in three material conditions: As-built, Hot Isostatic Pressed (HIP), heat-treated (AMS 5662) using a wrought Alloy 718 as reference. The comparison focuses on tool wear and surface integrity, including surface topography, residual stresses, and near-surface deformation. Machining tests were performed on small blade-shaped samples representative of a thin-walled aerospace component geometry. The results show clear differences in machinability between the two tool concepts. The cemented carbide tool is highly sensitive to the material condition, leading to higher surface roughness and lower compressive residual stresses compared to the BL-CBN tool. In contrast, the BL-CBN tool provides stable performance across all AM conditions. For the relatively short cutting lengths studied, machining-induced deformation remained low for both tools in the AM materials. However, wrought Alloy 718 material remains the most challenging material to machine, as it caused highest tool wear, deepest residual stresses and largest plastic deformation.