Many manufacturing sectors require high surface finishing. After machining operations such as milling or drilling, undesirable burrs or insufficient edge finishing may be generated. For decades, many finishing processes have been handmade-basis; this fact is accentuated when dealing with complex geometries especially for high value-added parts. In recent years, it’s a tendency of trying to automate as far as possible this kind of processes, repeatability and time/money savings are main purposes. Based on that idea, the aim of this work is to check new tools and strategies for finishing aeronautical parts, especially critical engine parts made on Inconel 718, a very ductile nickel alloy. Automating edge finishing of chamfered holes is a complicated but really important goal. In this paper, flexible abrasive tools were used for this purpose. A complete study of different abrasive possibilities was carried out, mainly focusing on roughness analysis and final edge results obtained.

Bubble (point defect) – a precursor of fuzz or under dense nanostructure formation is crystal lattice defect. Suitable selection of crystal lattice which inhibit Frenkel pair generation and intrinsically promotes self- interstitial solid solution strengthening contributes effectively towards making plasma facing material. For this, interstitial sites, their size, amount / fraction, positions, tendency of occupation and diffusion parameters (e.g. activation energies (Q), activation volumes) are determined. Fcc iron carbon alloys (austenitic stainless steels AISI / SAE 321, fcc structure, Pearson code cF4, space group Fm3̅m) are proposed as suitable candidates. Along with their room temperature fcc structure having 12 interstitial positions (4 octahedral, 6 coordination sites and 8 tetrahedral, 4 coordination sites / unit cell) to allow insertion of self (iron) atoms, they have excellent corrosion resistance, thermal conductivity, and non- magnetic properties. After their melting, casting, and machining to required dimensions and geometry, stabilizing heat treatment is applied to precipitate all carbon as TiC and prevent formation of Cr23C6 (sensitization). This resist heat and surface degradation and yield excellent architecture which not onlyinhibit Frankel pair generation but will also allow bulk assimilation or surface annihilation (loop punching) of this lattice point defect. A superior thermal, fluid, and structural design augment above. A second choice is presented as Co base superalloys owing to same fcc crystal structure and excellent properties (such as strength, dimensional stability, oxidation resistance) at high temperature.

Gamma titanium aluminides (γ-TiAl) present an excellent behaviour under high temperature conditions, being a feasible alternative to nickel-based superalloy components in aeroengine sector. However, considered as a difficult to cut material, process cutting parameters require special study to guarantee components quality. In this work, developed drilling mechanistic model is a useful tool in order to predict drilling force (F_z) and torque (T_c) for optimal drilling conditions determination. The model is validated for three types of Gamma-TiAl alloys. Integral hard metal end-drilling tools and different cutting parameters (feeds and cutting speeds) are tested in three different sized holes for each alloy.

Nickel-based superalloys are attractive to many industrial sectors (automotive, military, energy, aerospace etc.). However, their physical properties make them difficult to machining using traditional tools. Therefore, the new materials for the machining of Ni-based alloys are required. Ceramic-based composites could act as a tool to replace the current materials. The incentives for this paper are to provide an overview of existing ceramic composites and draw some conclusions that will help in solving the problem of choosing materials for processing of Ni-based superalloys. Despite the diversity of ceramic composites in this work the focus was on the SiAlON ceramic.

A Chinese superalloy GH4099 (~20 vol.% γ' phase), which can operate for long periods of time at temperatures of 1173-1273 K, was fabricated by electron beam melting (EBM). Argon gas atomized (AA) and plasma rotation electrode process (PREP) powders with the similar composition and size distribution were used as raw materials for comparison. Microstructure and mechanical properties of both the as-EBMed and post-treated alloy samples were investigated. The results show that the different powder characteristics resulted in the different build temperatures for AA and PREP samples, which were 1253 K and 1373 K, respectively. With increasing the building temperature, the EBM processing window shifted towards the higher scanning speed direction. Furthermore, intergranular cracking was observed for the as-fabricated PREP sample as a result of local enrichment of Si at grain boundaries. The cracks were completely eliminated by hot isostatic pressing (HIPing) and did not re-open during subsequent solution treatment and aging (STA). Fine spherical γ' phase precipitated uniformly after STA. The tensile strength of the HIP+STA samples was ~920 MPa in the building direction and ~850 MPa in the horizontal direction, comparable with that of the wrought alloy.