Review Regarding the Influence of Cryogenic Milling on Materials Used in the Aerospace Industry
Abstract
:1. Introduction
2. Main Materials Used in the Aeronautical Industry
2.1. Aluminum Alloys
2.2. Titanium Alloys
C | Fe | N | Al | O | V | H | Sn | Y | Zr | Mo | Si | Nb | Other | Ti | Refs. | |
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Titanium Ti6Al4V | <0.05 | <0.3 | <0.02 | 2.5–3.5 | <0.12 | 2–3 | <0.015 | - | <0.005 | - | - | - | - | 0.4 | Bal. | [55] |
Titanium Ti3Al2.5V | <0.05 | < 0.2 | <0.05 | 2.5–3.5 | < 0.15 | 2–3 | <0.015 | - | - | - | - | - | - | 0.35 | Bal. | [57,58] |
Titanium Ti5Al2.5V | <0.1 | <0.5 | <0.03 | 4–6 | <0.2 | - | <0.015 | 2–3 | - | - | - | - | - | 0.35 | Bal. | [51] |
Titanium Ti6-2-4-2S | 5.5–6.5 | <0.25 | - | - | - | - | - | 1.8–2.2 | - | 3.6–4.4 | 1.8–2.2 | 0.06–0.12 | - | - | Bal. | [59] |
IMI 834 | - | - | - | <5.8 | - | - | - | <4 | - | <3.5 | <0.5 | <0.35 | <0.7 | - | Bal. | [60] |
2.3. Nickel-Based Superalloys
2.4. Steel Alloys
2.5. Other Materials Used in Aircrafts
3. Cooling and Lubricating Fluids
4. Cryogenic Cooling
4.1. Delivery Methods in Cryogenic Cooling
4.2. Benefits and Features—Improved Machinability
- -
- Cooling materials to cryogenic temperatures can make them more brittle, which facilitates their cutting or machining, especially for tough or elastomeric materials but also for other materials such as titanium, inconel, or aluminum. Table 5 summarizes the papers that focus on the cryo-machining of materials used in the aerospace industry included in this review. The term “machinability” can be represented by the following criteria:
- -
- Surface finish;
- -
- Tool life;
- -
- Cutting force;
- -
- Chip shape;
- -
- Limiting rate of removed material [113].
Reference | Workpiece Material | Machining Outputs | Cooling Method | Obs. |
---|---|---|---|---|
[84] | Al 6082 | Flank wear Crater wear Surface roughness Topography and texture of the machined surface | Dry machining MQL LCO2 MQL + LCO2 | |
[102] | Al 6082-T6 | Cutting temperature Surface roughness Cutting forces Surface morphology Chip morphology Tool wear | LCO2 LN2 conventional wet machining | |
[106] | Al 8011 | Cutting temperature Surface roughness Tool wear Chip morphology Microstructure analysis Hardness | Dry machining conventional wet machining LCO2 MQL MQL + LCO2 | |
[114] | Al 7075 | Surface roughness Cutting temperature Cutting force | LN2 conventional wet machining | turning |
[115] | Al 7075 | Cutting force Surface roughness Chip morphology Tool wear Surface roughness | Dry machining LCO2 MQL MQL + LCO2 | |
[12] | Ti-6Al-4V | Cutting force | Dry machining LN2 | |
[24] | Ti-6Al-4V | Cutting force Tool wear Tool performance | conventional wet machining nano-MQL LN2 (internal and external) nano-MQL + LN2 | |
[83] | Ti-6Al-4V | Workpiece temperature Resulting forces Microhardness of the workpiece surface Surface topography | Dry machining LCO2 Sub-zero MWF | |
[104] | Ti-6Al-4V | Cutting temperature Surface roughness Chip morphology Cutting forces Tool wear Microhardness | Conventional wet machining LCO2 MQL + LN2 | |
[116] | Ti-6Al-4V | Surface roughness Tool wear Power consumption | Dry machining conventional wet machining cryogenic machining | |
[117] | Ti-3Al-2.5V | Power consumption | Dry machining MQL LN2 MQL + LN2 | |
[11] | Inconel 718 | Tool wear Cutting forces | MQL Conventional wet machining MQL + LCO2 | |
[13] | Inconel 625 | Surface roughness Tool wear Cutting temperature Chip morphology | MQL LN2 MQL + LN2 | |
[21] | Inconel 718 | Cutting force Tool wear | Conventional wet machining LCO2 (internal and external) MQL MQL + LCO2 | |
[66] | Inconel 718 | Tool wear Surface roughness | Dry machining LCO2 | |
[105] | Inconel 718 | Tool wear Energy consumption Chip reduction coefficient Surface roughness | Dry machining conventional wet machining LN2 | turning |
[118] | Inconel 718 | Surface roughness Residual stress Chip morphology Cutting force Tool wear | Dry machining High pressure jet LN2 MQL Nano-MQL | turning |
[119] | Inconel 718 | Surface roughness Tool wear Microhardness | Conventional wet machining MQL + LN2 | turning |
[120] | Inconel 718 | Tool wear Surface roughness Chip morphology | Dry machining Conventional wet machining LCO2 MQL + LCO2 | turning |
[121] | Inconel 718 | Tool wear Cutting forces Tool temperature | LCO2 internal and external | |
[107] | AISI-4037 | Surface roughness Cutting temperature Dimensional deviation Pattern and chip formation mode Cutting force | Dry machining Conventional wet machining LN2 | turning |
[122] | AISI 4340 | Surface roughness Cutting temperature | Dry machining LN2 | |
[91] | AISI 4041 | Tool wear Cutting temperature | Dry machining LN2 LCO2 MQL MQL + LCO2 | turning |
[103] | SiCp/Al composites | Cutting forces Chip morphology Surface topography | Dry machining LN2 |
4.2.1. Surface Finish
4.2.2. Tool Life
4.2.3. Cutting Force and Surface Stress
5. Conclusions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Cu | Zn | Mg | Mn | Fe | Si | Cr | Ti | Al | Refs. | |
---|---|---|---|---|---|---|---|---|---|---|
Al 2024 | 3.8–4.9 | <0.25 | 1.2–1.8 | 0.3–0.9 | <0.5 | <0.5 | <0.1 | <0.15 | Bal. | [45] |
Al 6061 | 0.15–0.4 | <0.25 | 0.8–1.2 | <0.15 | <0.7 | 0.4–0.8 | 0.04–0.35 | <0.15 | Bal. | [46,47] |
Al 7075 | 1.2–2.0 | 5.1–6.1 | 2.1–2.9 | <0.3 | <0.5 | <0.4 | 0.18–0.28 | <0.2 | Bal. | [48] |
Al 7150 | 1.2–1.9 | 7.2–8.2 | 2–2.9 | <0.2 | <0.2 | <0.15 | 0.1–0.22 | <0.1 | Bal. | [49] |
Al 7155 | 2–2.6 | 7.6–8.4 | 1.8–2.3 | <0.1 | <0.25 | <0.25 | <0.05 | <0.1 | Bal. | [50] |
Ni | Cr | Fe | Nb | Mo | Ti | Al | Mn | Si | C | Co | Other | Ref. | |
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Inconel 718 | 53 | 17 | 18.7 | 5.05 | 3.05 | 1.05 | 0.9 | 0.23 | 0.1 | 0.05 | - | Bal. | [66] |
Waspaloy | Bal. | 19.5 | - | - | 4.3 | 3 | 1.3 | - | - | 0.08 | 13.5 | 0.006B 0.06Zr | [67] |
Hastelloy X | Bal. | 22 | 18.5 | - | 9 | - | - | 0.5 | 0.5 | 0.1 | - | - | [68] |
Inconel 625 | Bal. | 22 | 3 | 3.5 | 9 | 0.2 | 0.1 | - | - | 0.01 | 0.1 | - | [67] |
Haynes 230 | Bal. | 22 | - | - | 2 | - | - | 1 | 0.5 | 0.075 | - | 12W | [69] |
Rene 41 | Bal. | 19 | - | - | 10 | 3.1 | 1.5 | - | - | 0.09 | 11 | 0.05B | [67] |
Fe | Ni | Cr | Mn | C | Mo | Si | S | P | Co | Other | Ref. | |
---|---|---|---|---|---|---|---|---|---|---|---|---|
AISI 4340 | 95–96 | 1.6–2 | 0.7–0.9 | 0.6–0.8 | 0.37–0.43 | 0.2–0.3 | 0.15–0.3 | 0.04 | 0.035 | - | - | [75] |
AISI 4037 | 98–98.6 | - | - | 0.7–0.9 | 0.35–0.4 | 0.2–0.3 | 0.15–0.35 | <0.04 | <0.035 | - | - | [76] |
AMS 6514 | Bal. | 18.5 | - | 0.1 | 0.03 | 4.8 | 0.1 | - | - | 9 | 0.6Ti 0.1Al | [77] |
AMS 6512 | Bal. | 18.5 | - | 0.1 | 0.03 | 4.8 | 0.1 | - | - | 7.5 | 0.4Ti 0.1Al | [78] |
AMS 6515 | Bal. | 18.5 | - | 0.1 | 0.03 | 4.8 | 0.1 | - | - | 12 | 1.4Ti 0.1Al | [79] |
Runs | ||||||||
---|---|---|---|---|---|---|---|---|
1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | |
Cutting speed, Vc (m/min) | 120 | 120 | 130 | 130 | 140 | 140 | 140 | 140 |
Feed rate, fz (mm/tooth) | 0.25 | 0.20 | 0.15 | 0.25 | 0.25 | 0.20 | 0.15 | 0.25 |
Depth of cut, ap (mm) | 0.5 | 0.7 | 0.5 | 0.3 | 0.7 | 0.5 | 0.5 | 0.7 |
Width of cut, ae (mm) | 0.4 | 0.2 | 0.2 | 0.2 | 0.4 | 0.4 | 0.2 | 0.4 |
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Nita, B.; Tampu, R.I.; Tampu, C.; Chirita, B.A.; Herghelegiu, E.; Schnakovszky, C. Review Regarding the Influence of Cryogenic Milling on Materials Used in the Aerospace Industry. J. Manuf. Mater. Process. 2024, 8, 186. https://doi.org/10.3390/jmmp8050186
Nita B, Tampu RI, Tampu C, Chirita BA, Herghelegiu E, Schnakovszky C. Review Regarding the Influence of Cryogenic Milling on Materials Used in the Aerospace Industry. Journal of Manufacturing and Materials Processing. 2024; 8(5):186. https://doi.org/10.3390/jmmp8050186
Chicago/Turabian StyleNita, Bogdan, Raluca Ioana Tampu, Catalin Tampu, Bogdan Alexandru Chirita, Eugen Herghelegiu, and Carol Schnakovszky. 2024. "Review Regarding the Influence of Cryogenic Milling on Materials Used in the Aerospace Industry" Journal of Manufacturing and Materials Processing 8, no. 5: 186. https://doi.org/10.3390/jmmp8050186