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<p>This study examines how controlled microstructural modification of WC–Co cutting tool inserts via WC grain size, sintering temperature, and Nano-Al₂O₃ reinforcement governs the mechanical properties and machining performance during the turning of Inconel 718. Four insert grades were investigated: coarse (2000–3000&#xa0;nm), medium (1000–2000&#xa0;nm), and fine (500–1000&#xa0;nm) WC–8 Co compositions sintered at 1375&#xa0;°C and 1450&#xa0;°C, along with a fine-grained WC–Co composite reinforced with 0.5 wt.% Nano-Al₂O₃ processed under identical conditions. Grain refinement increased hardness and wear resistance by limiting the binder mean free path, whereas elevated sintering temperature promoted WC grain coarsening, leading to reduced cutting-edge stability despite improved densification. Among all samples, the fine-grained insert sintered at 1450&#xa0;°C exhibited the most balanced performance, achieving a hardness of 1676 HV30, fracture toughness of 9.6&#xa0;MPa·m^1/2, minimum cutting force of 265 N, and extended tool life of 12&#xa0;min. Nano-Al₂O₃ reinforcement further enhanced fracture toughness (12.2&#xa0;MPa·m^1/2) via crack deflection and bridging; however, it reduced hardness and accelerated tool wear at higher cutting speeds. Unlike prior studies that typically isolate compositional or processing effects, this work establishes a direct, experimentally validated microstructure–property–machining performance linkage, enabling identification of optimal WC–Co insert architectures for machining high-temperature nickel-based superalloys.</p>

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Influence of WC–Co cutting tool insert modifications on the machinability of Inconel 718

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月20日

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  • Shashidhar M. Kotian,
  • K. S. Narayanaswamy,
  • Dasharath S. M.,
  • Vishnu V. Balakrishnan,
  • Basil Kuriachen

摘要

This study examines how controlled microstructural modification of WC–Co cutting tool inserts via WC grain size, sintering temperature, and Nano-Al₂O₃ reinforcement governs the mechanical properties and machining performance during the turning of Inconel 718. Four insert grades were investigated: coarse (2000–3000 nm), medium (1000–2000 nm), and fine (500–1000 nm) WC–8 Co compositions sintered at 1375 °C and 1450 °C, along with a fine-grained WC–Co composite reinforced with 0.5 wt.% Nano-Al₂O₃ processed under identical conditions. Grain refinement increased hardness and wear resistance by limiting the binder mean free path, whereas elevated sintering temperature promoted WC grain coarsening, leading to reduced cutting-edge stability despite improved densification. Among all samples, the fine-grained insert sintered at 1450 °C exhibited the most balanced performance, achieving a hardness of 1676 HV30, fracture toughness of 9.6 MPa·m^1/2, minimum cutting force of 265 N, and extended tool life of 12 min. Nano-Al₂O₃ reinforcement further enhanced fracture toughness (12.2 MPa·m^1/2) via crack deflection and bridging; however, it reduced hardness and accelerated tool wear at higher cutting speeds. Unlike prior studies that typically isolate compositional or processing effects, this work establishes a direct, experimentally validated microstructure–property–machining performance linkage, enabling identification of optimal WC–Co insert architectures for machining high-temperature nickel-based superalloys.