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<p>This study examines the machinability of Stainless steel SS309L, and Inconel 625 thin walls fabricated by Wire Arc Additive Manufacturing (WAAM), produced both as single materials and as bimetallic structures with different deposition sequences. Drilling and milling experiments were conducted under dry, pure MQL, and nanofluid-assisted MQL conditions using graphene nanoplatelet (GNP) and multi-walled carbon nanotube (MWCNT) additives. Build-direction-controlled microstructures—lathy versus skeletal ferrite in SS309L and cellular versus dendritic morphology in Inconel 625—resulted in varied machining responses, in single material depositions. For bimetallic cases, SS309L-first builds exhibited stable cutting forces across building direction, whereas Inconel-first deposited configurations showed up to 40% higher forces in interface region due to abrupt thermal transitions and Ni–Fe elements compositional inhomogeneity. Nanofluid performance was microstructure-dependent: standard MQL worsened performance in cellular regions, while MWCNT nanofluid reduced cutting forces in interface region by 37.5%, minimized tool wear and BUE, and provided the most robust lubrication across heterogeneous microstructures and elemental transitions. This study indicates the importance of deposition-sequence and microstructure-aware lubrication strategies in WAAM post-processing.</p>

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Microstructure-guided selection of nanofluid-assisted MQL strategies for machinability of WAAM-fabricated stainless steel–inconel bimetallic structures

  • 期刊论文

  • 发表日期：

    2025年10月31日

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  • Ozan Can Ozaner,
  • Yafes Çavuş,
  • Şener Karabulut,
  • Halil Karakoç,
  • Abhay Sharma,
  • Reza Talemi,
  • Tegoeh Tjahjowidodo

摘要

This study examines the machinability of Stainless steel SS309L, and Inconel 625 thin walls fabricated by Wire Arc Additive Manufacturing (WAAM), produced both as single materials and as bimetallic structures with different deposition sequences. Drilling and milling experiments were conducted under dry, pure MQL, and nanofluid-assisted MQL conditions using graphene nanoplatelet (GNP) and multi-walled carbon nanotube (MWCNT) additives. Build-direction-controlled microstructures—lathy versus skeletal ferrite in SS309L and cellular versus dendritic morphology in Inconel 625—resulted in varied machining responses, in single material depositions. For bimetallic cases, SS309L-first builds exhibited stable cutting forces across building direction, whereas Inconel-first deposited configurations showed up to 40% higher forces in interface region due to abrupt thermal transitions and Ni–Fe elements compositional inhomogeneity. Nanofluid performance was microstructure-dependent: standard MQL worsened performance in cellular regions, while MWCNT nanofluid reduced cutting forces in interface region by 37.5%, minimized tool wear and BUE, and provided the most robust lubrication across heterogeneous microstructures and elemental transitions. This study indicates the importance of deposition-sequence and microstructure-aware lubrication strategies in WAAM post-processing.