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Laser-induced oxidation-assisted micromilling of deep narrow microgroove on Inconel 718

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Abstract

The miniaturized components of Inconel 718 superalloy are widely used in aerospace industries due to its excellent properties at elevated temperatures. In this work, an innovative hybrid processing technology named laser-induced oxidation assisted micromilling (LOMM) was proposed. A deep narrow microgroove with a depth of 1500 μm and a width of 500 μm was fabricated successfully by LOMM. The effects of average laser power on morphology and microstructure of the oxide layer and sub-layer were studied. In addition, milling force, surface quality of the machined microgrooves, and tool wear were investigated. Under laser irradiation with average laser power of 4.5 W, a loose and soft oxide layer, as well as a sub-layer were formed, whose thicknesses were 24 μm and 16 μm, respectively. The milling force during removing of the oxide layer was only around 1.2 N, which was much lower than that (3~8 N) when removing of the substrate material. Owing to the low cutting force, no obvious tool wear was observed in removing of the oxide layer. However, tool wear in terms of coating peeling and microchipping was found in micromilling of the sub-layer and substrate material. For comparison, conventional micromilling (COMM) was used to machine a deep narrow microgroove under identical milling parameters. The tool diameter was reduced by 4.4% in LOMM, while that was reduced by 22% in COMM. The tool failure forms in COMM were catastrophic nose breakage and severe coating peeling. The bottom surface roughness Sa of the deep narrow microgroove machined with LOMM was 0.21 μm, while that machined with COMM reached 0.41 μm. This study validated that the proposed novel hybrid process can prolong tool life, and improve surface quality and material removal rate.

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Funding

This work was supported by the National Natural Science Foundation of China [Grant No. 52075255 & 51975288], and the China Postdoctoral Science Foundation (No. 2019M661823), and the Foundation of the Graduate Innovation Center, Nanjing University of Aeronautics and Astronautics (No. kfjj20200505).

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People’s Republic of China

    Lianjia Xin, Guolong Zhao, Yinfei Yang & Liang Li

  2. Beijing Spacecrafts, Beijing, 100094, People’s Republic of China

    Bin Zhang & Hanliang Liu

Authors
  1. Lianjia Xin
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  2. Bin Zhang
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  3. Guolong Zhao
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  4. Hanliang Liu
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  5. Yinfei Yang
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  6. Liang Li
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Contributions

Mr. Xin Lianjia conducted the experiments, interpreted the results, and wrote the manuscript. Mr. Zhang Bin conducted the analysis, and checked the manuscript. Dr. Zhao Guolong designed the study, and designed the experimental setup. Mr. Liu Hanliang analyzed the tool wear mechanisms. Dr. Yang Yinfei analyzed the surface morphology. Dr. LI Liang contributed to the discussion and background of the study. All authors commented on the manuscript draft and approved the submission.

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Correspondence to Guolong Zhao.

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Xin, L., Zhang, B., Zhao, G. et al. Laser-induced oxidation-assisted micromilling of deep narrow microgroove on Inconel 718. Int J Adv Manuf Technol 114, 173–184 (2021). https://doi.org/10.1007/s00170-021-06854-5

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  • DOI: https://doi.org/10.1007/s00170-021-06854-5

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