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<p>The application of laser-clad coatings reinforced with tungsten carbide (WC) particles is an effective method to enhance the performance of nickel-based materials. Poor machinability of high-performance metal matrix composites (MMC) fabricated by laser powder directed energy deposition (LP-DED) remains a major barrier to their application in extreme environments. In this study, the machinability of LP-DED manufactured 40 wt% WC<sub>p</sub>/IN718 was investigated through micro-milling experiments. Cutting force monitoring and multi-scale surface morphology characterization were carried out to study the influence of spindle speed, feed per tooth, and axial depth of cut. The results show that spindle speed and feed rate have the strongest impact on cutting forces and surface topography, while the axial depth of cut has a smaller effect. A suitable process window was identified at a spindle speed of 14,000&#xa0;rpm and a feed rate of 6&#xa0;μm/z, where the cutting force decreased to 5.35&#xa0;N and the surface roughness (<i>Sa</i>) reached a minimum of 0.311&#xa0;μm. Through parameter optimization, the cutting force and surface roughness were reduced by 18% and 13% resulting in stabilized cutting forces and an improved surface finish. The principal milling-induced impairments to surface integrity are fractures, pits, scraping, matrix coating, and flaking. The production of damage is primarily dictated by the failure mechanisms of the primary WC particles, which include compressive breakage, intragranular fracture, particle pullout, and interface debonding, in conjunction with the high ductility of the IN718 matrix, leading to matrix coating. The growth of this defect is ultimately governed by the interaction between the cutting edge and the reinforcing particles. Thus, this study offers direction for parameter selection and damage prevention in the high-efficiency, high-precision machining of LP-DED fabricated WC<sub>p</sub>/IN718.</p>

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Study on machinability of LP-DED manufactured 40 wt% WCp/IN718 composite by micro-milling

  • 期刊论文

  • 发表日期：

    2026年7月30日

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  • Zongquan Li,
  • Lei Yan,
  • Li Zhu,
  • Kun Liu,
  • Liang Li,
  • Guolong Zhao

摘要

The application of laser-clad coatings reinforced with tungsten carbide (WC) particles is an effective method to enhance the performance of nickel-based materials. Poor machinability of high-performance metal matrix composites (MMC) fabricated by laser powder directed energy deposition (LP-DED) remains a major barrier to their application in extreme environments. In this study, the machinability of LP-DED manufactured 40 wt% WCp/IN718 was investigated through micro-milling experiments. Cutting force monitoring and multi-scale surface morphology characterization were carried out to study the influence of spindle speed, feed per tooth, and axial depth of cut. The results show that spindle speed and feed rate have the strongest impact on cutting forces and surface topography, while the axial depth of cut has a smaller effect. A suitable process window was identified at a spindle speed of 14,000 rpm and a feed rate of 6 μm/z, where the cutting force decreased to 5.35 N and the surface roughness (Sa) reached a minimum of 0.311 μm. Through parameter optimization, the cutting force and surface roughness were reduced by 18% and 13% resulting in stabilized cutting forces and an improved surface finish. The principal milling-induced impairments to surface integrity are fractures, pits, scraping, matrix coating, and flaking. The production of damage is primarily dictated by the failure mechanisms of the primary WC particles, which include compressive breakage, intragranular fracture, particle pullout, and interface debonding, in conjunction with the high ductility of the IN718 matrix, leading to matrix coating. The growth of this defect is ultimately governed by the interaction between the cutting edge and the reinforcing particles. Thus, this study offers direction for parameter selection and damage prevention in the high-efficiency, high-precision machining of LP-DED fabricated WCp/IN718.