Surface integrity and fatigue life of Inconel 718 by ultrasonic peening milling

Yin, Xiaoming; Li, Xun; Liu, Yihang; Zhang, Deyuan

doi:10.1016/j.jmrt.2022.12.019

Cited by 20 publications

(6 citation statements)

References 46 publications

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“… UPMed 3D surface topography of S3: ( a ) surface measurement topography, ( b ) stereoscopic topography, and ( c ) detailed topography; v c = 100 m/min, s = 5358 rpm [ 120 ]. …”

Section: Figurementioning

confidence: 99%

“…Moreover, UPM resulted in a more extensive plastic deformation region with a t ≤ 15.2 µm. Yin et al [120] studied UPM technology based upon INCONEL ® 718 machining t investigate the vibration's effect on this material's surface integrity and fatigue life afterwards comparing the results with those obtained by CM. Compared with the CM (Figures 35 and 36) processing of the INCONEL ® 718, UPM significantly altered th microstructure and roughness of the machined surface (Figure 37).…”

Section: Additive Manufacturing (Am)mentioning

confidence: 99%

“…Nonetheless, it yields an elevated surface micro-hardness, increased surface CRS and a greater thickness of the micro-hardening layer, measured approximately 9.9-15.2 µm via UPM, whereas it resulted in 5.6-8.2 µm via CM. The hybrid process can considerably improve the fatigue life of INCONEL ® 718 since a workpiece made by UPM has a 17.12× higher fatigue life than CM under the same processing conditions.Yin et al[120] studied UPM technology based upon INCONEL ® 718 machining to investigate the vibration's effect on this material's surface integrity and fatigue life, afterwards comparing the results with those obtained by CM. Compared with the CM (Figures35 and 36) processing of the INCONEL ® 718, UPM significantly altered the microstructure and roughness of the machined surface (Figure37).…”

mentioning

confidence: 99%

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An In-Depth Exploration of Unconventional Machining Techniques for INCONEL® Alloys

Pedroso,

Sebbe,

Silva

et al. 2024

Materials

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Build-up-edge (BUE), high-temperature machining and tool wear (TW) are some of the problems associated with difficult-to-machine materials for high-temperature applications, contributing significantly to high-cost manufacturing and poor tool life (TL) management. A detailed review of non-traditional machining processes that ease the machinability of INCONEL®, decrease manufacturing costs and suppress assembly complications is thus of paramount significance. Progress taken within the field of INCONEL® non-conventional processes from 2016 to 2023, the most recent solutions found in the industry, and the prospects from researchers have been analysed and presented. In ensuing research, it was quickly noticeable that some techniques are yet to be intensely exploited. Non-conventional INCONEL® machining processes have characteristics that can effectively increase the mechanical properties of the produced components without tool-workpiece contact, posing significant advantages over traditional manufacturing.

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“… UPMed 3D surface topography of S3: ( a ) surface measurement topography, ( b ) stereoscopic topography, and ( c ) detailed topography; v c = 100 m/min, s = 5358 rpm [ 120 ]. …”

Section: Figurementioning

confidence: 99%

Section: Additive Manufacturing (Am)mentioning

confidence: 99%

mentioning

confidence: 99%

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An In-Depth Exploration of Unconventional Machining Techniques for INCONEL® Alloys

Pedroso,

Sebbe,

Silva

et al. 2024

Materials

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show abstract

“…After the fatigue test, the residual tensile strength of the sample improved, reaching 95.8% of the original tensile strength. Yin et al (2023) conducted fatigue tests on nickel-based superalloys using ultrasonic peening milling (UPM) and conventional milling (CM) and found that UPM significantly extended the fatigue life of the specimens. Compared with CM, the average life of the UPM milled specimens increased by 16.12 times (Figure 12).…”

Section: In-service Functional Performance 31 Fatigue Resistancementioning

confidence: 99%

Ultrasonic vibration cutting of advanced aerospace materials: a critical review of in-service functional performance

Peng,

Han,

Wang

et al. 2024

JIMSE

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PurposeUnconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.Design/methodology/approachThe surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.FindingsTo address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.Originality/valueThis study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

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“…In the field of plastic forming, compared with plastic tensile instability (fracture) and compressive instability (wrinkling) of sheet metal after exceeding the minimum bending radius [10,11], residual stress and strain, as the results of plastic forming, cannot directly incur the forming failure of components [12], therefore, researchers in this field are more concerned on loading process but not unloading process. But in the field of milling, residual strain and stress directly impact the surface integrity after milling such as surface roughness, microhardness, fatigue properties [13,14], etc.…”

mentioning

confidence: 99%

Gradient thickness-dependent distribution of residual stress and springback of thin-walled TC4 titanium alloy sheet with variable thickness in collaborative manufacturing process of pre-plastic forming and milling

SHU,

REN,

ZHANG

et al. 2024

Preprint

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Thin-walled sheet components with variable thickness and complex curved surface are expanding considerably in the advanced manufacturing field of aerospace industry due to its aerodynamic shape and light-weight characteristics, and collaborative manufacturing method of pre-plastic forming and milling was used to solve the problems of low rough milling efficiency and large milling difficult of such components. However, the structural characteristics of thin-walled and variable thickness brought the problems of residual stress and springback after pre-plastic forming, which impacted the milling quality and increased milling allowance in subsequent milling. In this work, based on three-point bending tests of thin-walled TC4 titanium alloy sheets with different ratio of thickness variation (ζ) and its Finite Element Analyze (FEA), gradient thickness-dependent distribution of residual stress and springback after pre-plastic forming was systematically studied. The results showed that with the ζ increasing from 1 to 6, difference of residual stress (Δσres) between both sides increased from 0 to 356.81 MPa, difference of springback (ΔS) between both sides increased 0 to 0.23 mm, and Springback Angle (SA) increased from 11.02 ° to 11.88 °, which was due to the increasing of stress component along the breadth direction and the decreasing of strain component along the thickness direction, and specimen #5 (ζ = 3) had more uniform distribution of residual stress. In addition, through considering the decay of elastic modulus (E) after plastic deformation, absolute error of SA of specimen #6 (ζ = 6) was reduced from 1.98 ° to 0.95 °.

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Surface integrity and fatigue life of Inconel 718 by ultrasonic peening milling

Cited by 20 publications

References 46 publications

An In-Depth Exploration of Unconventional Machining Techniques for INCONEL® Alloys

An In-Depth Exploration of Unconventional Machining Techniques for INCONEL® Alloys

Ultrasonic vibration cutting of advanced aerospace materials: a critical review of in-service functional performance

Gradient thickness-dependent distribution of residual stress and springback of thin-walled TC4 titanium alloy sheet with variable thickness in collaborative manufacturing process of pre-plastic forming and milling

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