The International Journal of Advanced Manufacturing Technology (2021) 112:1941–1950

https://doi.org/10.1007/s00170-020-06471-8

ORIGINAL ARTICLE

Machined surface integrity of inconel 718 in high-speed dry milling

using SiAlON ceramic tools
Farhad Molaiekiya 1 & Ali Aliakbari Khoei 1 & Maryam Aramesh 1 & Stephen C. Veldhuis 1

Received: 1 August 2020 / Accepted: 7 December 2020 / Published online: 5 January 2021
# Springer-Verlag London Ltd., part of Springer Nature 2021

Abstract
The surface integrity of complex engineering components has a major effect on their mechanical properties. Recently, modern
ceramic tools have demonstrated themselves as potential candidates for high-speed machining of heat-resistant superalloys,
delivering a substantial increase in productivity. The results of previous studies showed that after surpassing a cutting speed of
800 m/min, the cutting forces experienced a sharp decrease accompanied by a reduction in tool wear. However, in such
applications, extreme temperature and mechanical loads are generated at the cutting zone, implying a possible negative influence
on the machined surface integrity. In this study, numerous characterizations have been performed to evaluate the different aspects
of inconel 718–machined surface integrity after face milling with SiAlON cutting tools at the range of 900 m/min. Since the
cutting conditions are remarkably far from those experienced during conventional cutting, the results are also compared to those
obtained during conventional milling of inconel with a commonly used commercial coated carbide tool. Results showed that the
milling process induces tensile residual stresses as high as 2 GPa on the machined surface while generating an unwanted white
layer with a thickness of around 1 μ and a relatively rough surface with Ra = 4.5 μm as compared to surfaces machined with
conventional carbide tools at Ra = 2.2 μm. No major work-hardening effect was observed. Nevertheless, imperfections were
observed to be contained within a thin sub-layer of the workpiece, suggesting that the ceramic tools can be used for roughing
processes provided further finishing operations performed to remove the damaged layer.

Keywords High-speed machining . Cutting parameters . Surface integrity . SiAlON ceramic . Inconel 718

1 Introduction cutting speeds for the milling of hardened IN718 provides a

significant improvement in the machinability of this material.
Inconel 718 (IN718) is a heat-resistant superalloy that is wide- Studies showed that even at 500 m/min, the cutting forces
ly employed when making engineering components that are were so high that the ceramic inserts were completely
subjected to high thermomechanical loads, especially in the shattered after a few seconds of machining. However, surpris-
aerospace industry. However, because of its high-temperature ingly, by increasing the speeds to 900 m/min, the forces were
shear strength, low thermal conductivity, and extensive ten- abruptly reduced by 70%, leading to a considerable increase in
dency to work hardening, IN718 is considered one of the most the tool life. This behavior under extreme conditions was at-
difficult-to-cut alloys. The low machinability of this material tributed to the noticeable change in the localized microstruc-
can lead to rapid tool wear, limited material removal rate, ture of inconel related to some of its unique strengthening
excessive use of coolant, or poor surface integrity [1–4]. mechanisms and fluid-like flow of deformed material at high
Recent studies by the authors show that using a SiAlON temperature and high strain rates [5].
ceramic tool under extreme conditions associated with high Implementing the concepts of high-speed machining for
IN718 has proven to be a cost-effective solution that can elim-
inate the use of coolant while achieving an unprecedented
* Farhad Molaiekiya material removal rate with an acceptable tool life [6, 7]. But,
[email protected]
since most of the industrial inconel components are used in
demanding applications such as rotating parts, operating at
1
Department of Mechanical Engineering, McMaster Manufacturing high-temperature corrosive conditions in a gas turbine, surface
Research Institute (MMRI), McMaster University, 1280 Main Street
West, Hamilton, Ontario L8S 4L7, Canada
integrity and microstructural reliability of manufactured parts
1942 Int J Adv Manuf Technol (2021) 112:1941–1950

are of prime importance preventing catastrophic premature scanning, XRD measurements, cross section metallography,
failure of the components under service, especially following nano-indentation, and SEM/EDS to study and control the sur-
a high-speed intermittent cut at dry conditions [8, 9]. face roughness, residual stress, work-hardening, microstruc-
In high-speed machining of nickel-based superalloys, the tural alterations, surface inclusion and contamination, grain
low thermal conductivity of the workpiece generates very distortion, cracks, and heat-affected zones and other imperfec-
high temperatures, which leads to undesired thermal effects tions on the machined workpiece.
resulting in poor surface integrity of the machined surface [10,
11]. Also, a high shear strength and a high strain-hardening
rate of inconel under extreme deformation mean there is a 2 Materials and methods
possibility of mechanically induced imperfections during ma-
chining. Previous studies also report the formation of exces- 2.1 Experimental setup and machines
sive built-up edge and transferred layers during the milling
process [12, 13]. The unstable nature of this phenomenon Machining experiments were performed using a robust high-
can lead to the development of attrition wear patterns on the speed CNC machine center (Makino MC56-5XA) with
tool and poor surface quality of the finished product. These are 30 kW spindle power and 15,000 maximum RPM, as shown
critical issues as the roughness of the surface plays a promi- in Fig. 1a.
nent role in the resistance to creep and fatigue of the compo-
nent [14, 15]. Since in high-speed machining with ceramic 2.2 Workpiece material
inserts, the tool life flank wear–based criterion is defined to
be more than a conventional flank wear criteria for tungsten The workpiece material was a block of 45 HRC age-hardened
carbide tools, the roughness of the final machined surface can IN718. The chemical composition of the workpiece consists
be compromised but needs to be monitored carefully. approximately of 53.7% Ni, 18.4% Cr, 18.3% Fe, 6.4% Nb,
Therefore, comprehensive investigations need to be per- and Al, Ti, and Si (1% of each) in weight percentage. The
formed on the surface and sub-surface of a machined IN718 yield strength and tensile strength of the workpiece are 1230
component to understand the impact on surface roughness and and 1490 MPa, respectively. IN718 has an extremely low
surface texture, sub-layer plastic deformation and work-hard- thermal conductivity of around 12 W/m.K, and its melting
ening, near-surface microstructural defects and inclusions, point is between 1250 and 1300 °C.
and residual stress after high-speed dry milling with SiAlON
ceramic tools. 2.3 Cutting tools
Evaluation of machinability and surface integrity of IN718
parts has been a topic of interest during the past few decades The SiAlON ceramic cutting tool used in this study was a
[11, 16–20]. Many researchers attempted to characterize the Kennametal KCRA250RN4306S075L175 indexable face
properties of the inconel-machined surface and sub-surface; mill with 10° clearance, − 10° axial rake, and − 5° radial rake
however, most of the studies are focused around turning with angle. The grade of the SIALON tool was KYS30
common carbide tools at conventional conditions, with a few (Kennametal RNGN120400T01020 round milling inserts).
using ceramic tooling. High tensile residual stress is consid- For the sake of comparison, a similar tool geometry was also
ered the most common phenomenon observed during machin- tested using a state-of-the-art coated tungsten carbide inserts.
ing of heat-resistant alloys [9, 18]. Also, an increase in sub- The geometry of the tools is shown in Fig. 1a. The inserts were
surface hardness is reported by some researchers that is attrib- chosen from Kennametal KC725M grade TiAlN PVD–coated
uted to strain hardening sensitivity of the material in plastic carbide inserts clamped on a KDR250R1207S075L200 shell
deformations [19, 21, 22]. mill.
Considering the lack of significant data on high- Flank and volumetric tool wear were measured using a
performance dry milling of hardened IN718 with SiAlON Keyence VHX-5000 and Alicona focus variation microscope.
ceramic tools and the possible damaging effects that extreme Flank wear of 300 and 1000 microns were selected as the end-
heat and deformations of such a process can induce on the life of-tool-life criterion for cemented carbide and ceramic inserts,
expectancy of a sensitive product, a comprehensive study is respectively.
presented in this paper aiming to investigate the major aspects
of surface integrity. Furthermore, wherever possible, the re- 2.4 Machining condition and cutting parameters
sults of the experiments and characterizations are compared to
the outcome of a conventional cutting process using a com- Based on the result of the previous studies, the cutting speed
mon coated WC-Co tool. of 900 m/min was selected for the SiAlON ceramics as the
Various machinability experiments and characterization cutting forces were found to be minimum at this speed, and the
techniques have been used in this research such as 3D surface tool life longest. VC = 35 m/min was selected for the carbide
Int J Adv Manuf Technol (2021) 112:1941–1950 1943

Fig. 1 a Machinability experiment setup. b Geometry of the face milling tool used

insert with a flood coolant turned on. Various axial depths of force, 5-s dwell time, and 10 mN/min loading/unloading rate.
cut (1–3 mm) were selected to investigate the effect of increas- The results were analyzed using the Oliver-Pharr nonlinear
ing productivity (material removal rate), by increasing the curve fit method. The indentations were extended up to
depth of cut, on the characteristics of the workpiece surface. 100 μm in depth from the machined surface at a 1-μm
resolution.
For residual stress measurement, the sectioned samples
2.5 Experimental machine and measurement system
were mounted on the Bruker D8 Discover with Davinci design
diffractometer. The instrument is equipped with a cobalt-
Flank and volumetric tool wear were measured using a
sealed tube source (λavg = 1.79026 Å) and the power settings
Keyence VHX-5000 and Alicona focus variation microscope.
of 35 kV and 45 mA. The Phi angles of 0°, 72°, 144°, 216°,
Flank wear of 300 and 1000 microns were selected as the end-
and 288° were selected. For each phi angle, the chi angle is
of-tool-life criterion for cemented carbide and ceramic inserts,
changed to 10°, 30°, and 50°. The frame exposure time was
respectively.
420 s/frame, and the data were collected in the range of 104–
Optical microscopic observations were done using a
126°. 2D frames were processed with DIFFRAC measure-
Keyence VHX-5000 and Keyence VH-ZST. To reveal the
ment suite version 6.5 and analyzed in Leptos V7. A picture
microstructure, the material was etched by swabbing a cotton
of the setup is shown in Fig. 2.
ball rinsed in a solution consisting of 15 ml hydrochloric acid,
10 ml nitric acid, 10 ml acetic acid, and less than a drop of
glycerin for 10 s.
A High-precision 3D optical microscope (Alicona
Infinite Focus XL200 G5) with 2-μm vertical and 5-μm
lateral scanning resolution was used to scan and measure
the roughness of the surfaces based on the ISO 4288
standard. Further microscopic observations were done
using a Tescan Vega II LSU scanning electron micro-
scope (SEM), equipped with an Oxford X-Max 80
energy-dispersive X-ray spectroscopy (EDX) detector
and the Inca software version 4.14. The spatial resolution
of the EDS data was set to 1–5 μm3 for low and 0.2–1
μm3 for high atomic numbers using a 10-kV accelerating
voltage.
Sub-surface nano-hardness was measured using an Anton
Paar NHT3 nano-indentation tester. The indentations were
done using a sharp Berkovich indenter with 35 mN maximum Fig. 2 Setup for residual stress measurements
1944 Int J Adv Manuf Technol (2021) 112:1941–1950

3 Results and discussions are shown in Fig. 5, and the (Sa) values were measured equal
to 0.66 ± 0.1 μm and 1.10 ± 0.1 μm, respectively. The rough-
3.1 Tool wear and tool life studies ness of the workpiece surface generated by the worn tools was
also evaluated, and the results can be seen in Table 1. There
Tool wear curves obtained for both ceramic and cemented are many factors affecting the surface roughness; the most
carbide tools are depicted in Fig. 3. The criteria for the end reported is the cutting parameters, especially the feed rate.
of tool life were selected based on common industrial prac- Despite the lower feed rate and higher cutting speed of the
tices. The SiAlON ceramic tool machined IN718 for a total of SiAlON tool, the surface roughness at the end of tool life is
4410 mm in feed length until the end of life, while the coated worse than the roughness generated by the carbide tool, which
carbide tool traveled for 3360 mm, 25% less. Furthermore, in is a result of higher tool wear and change in the geometry of
terms of productivity of the process, the SiAlON tool also the cutting edge. Meanwhile, the surface that is machined
delivered four times higher material removal rate compared using worn ceramic tools shows much higher RZ value
with the carbide tool. During the machinability experiments, representing more random grooves which can be the result
SiAlON ceramics showed steady and repeatable 3D wear vol- of external particles getting stuck between the tool and work-
ume and flank wear rate in various experiments and is be- piece abrading the machined surface at the tertiary shear de-
lieved to be able to perform similarly until 2-mm flank wear formation zone.
if the right cutting conditions are implemented. The cutting High-speed milling of IN718 with SiAlON ceramics
speed of 900 m/min was selected based on the outcome of produced an extensive amount of built-up layers on the
previous research aimed at the highest tool life and the lowest cutting edges. As the tool wear evolved, the unstable
cutting force and tool chipping. The selection of cutting pa- built-up layer can detach from the tool and stick on the
rameters was performed within a range of speeds between 500 workpiece surface. Not only does this phenomenon cause
and 1300 m/min while investigating various aspects of the dimensional inaccuracy and an increase in surface rough-
cutting process such as tool wear mechanism, cutting forces, ness but also can transfer unwanted elements from the
chip formation, built-up layers, and tribology at high speeds tool material to the machined surface. SiAlON or silicon
[5, 23]. aluminum oxynitride contains a high percentage of Si.
Silicon and other non-metallic contaminations such as
3.2 Surface roughness/texture silica and alumina are known to be a source of reduction
in fatigue life in aerospace components by creating
The roughness and texture of the machined surfaces were inclusion-initiated cracks.
examined for different tools. Figure 4 illustrates the topogra- Figure 6 shows the contamination of the workpiece surface
phy of surfaces captured by the Alicona focus variation mi- after high-speed milling with ceramic tools at VC = 900
croscope. For the SiAlON ceramic tool cutting at VC = 900 m/ m/min. Thus, a final finishing pass is still required if a
min and FZ = 40 μm/tooth, the roughness of the surface pro- SiAlON tool is used for the roughing of high-temperature
duced by a fresh tool was 0.52 ± 0.11 μm, while the roughness aerospace engine parts. This phenomenon intensified as the
of the fresh carbide tools was measured to be 0.82 ± 0.07 μm tool wear further evolves and, in some cases, can generate
at VC = 35 m/min and FZ = 200 μm/tooth. The surface textures signs of material pull-out on the workpiece surface as can be

Fig. 3 Tool life curves obtained

for WC-Co (35 m/min) and
SiAlON ceramic (900 m/min)
Int J Adv Manuf Technol (2021) 112:1941–1950 1945

Fig. 4 Surface topography of the machined IN718 with sharp tools. a SiAlON Ceramic tool. b PVD-coated WC-Co tool

seen in microscopic images of the machined surface in Fig. 7 distortions, or excessive plastic deformations. However,
and the cross section in Fig. 8d. the sub-surface cross section of the workpieces after ma-
chining with a worn tool, especially at the location of
3.3 Sub-surface integrity built-up edge irregularities, shows cracks and pits which
have a negative influence on the tensile and fatigue
In Fig. 8a and b, the generated surface after a few passes strength of the part.
of high-speed milling with sharp ceramic tools shows no A 1–2-μm hardened layer known as a white layer is
sign of major sub-surface damages, cracks, grain observed to be formed on the machined surface after
high-speed machining (Fig. 9). This layer is usually seen
during processes involving rapid heating and cooling cy-
cles or on surfaces that experienced extreme frictional
conditions [24–26]. Extreme thermomechanical loads re-
sult in microstructure refinement and dynamic recrystal-
lization that are believed to be mechanisms behind the
formation of white layers after machining

Table 1 Surface roughness and texture measurements for the worn

tools

Tool Worn SiAlON Worn WC-Co

Cutting parameters VC = 900 m/min VC = 35 m/min

FZ = 40 μm/tooth FZ = 200 μm/tooth
Axial DOC = 1 mm Axial DOC = 1 mm
Ra 4.50 ± 0.64 μm 2.19 ± 0.22 μm
Rz 16.61 ± 1.7 μm 4.90 ± 0.39 μm
Fig. 5 Texture illustration of the machined surfaces at the end of tool life Sa 4.42 ± 0.89 μm 2.38 ± 0.34 μm
by (a) Worn SiAlON ceramic and (b) worn PVD-coated WC-Co
1946 Int J Adv Manuf Technol (2021) 112:1941–1950

Fig. 6 Detached build-up layers

stick on the machined surface. a
Alicona microscope scans show-
ing irregularity on the surface. b
SEM graph of the built-up trans-
ferred layer. c EDS elemental
studies of the adhered BUE to the
workpiece
EDS 1

(a) (b)
(wt%)
EDS 1
Ni 50.14 Nb 4.22 Si 0.26

Fe 16.82 Ti 0.74

Cr 17.06 Al 0.41

(c)

3.4 Sub-surface nano-hardness axial depth of cut was also investigated in this experiment and
showed no major influence on the work-hardening level of the
The nano-hardness of the white layer was measured to be sub-layer. Increasing the axial depth of cut is the easiest way
close to 21 GPa using a sharp Berkovich indenter under a to increase the material removal rate of the machining process.
10-mN load. The nano-hardness of the machined cross sec- The same measurement for WC-Co tools under wet condi-
tions was measured using 35-mN load indentations with a tions shows approximately a 10% higher hardness value as
sharp Berkovich diamond indenter. As illustrated in Fig. 10, compared to samples produced at high cutting speeds using
no major sub-surface hardening is observed after high-speed SiAlON tooling.
machining with SiAlON tools. The hardness of the bulk of the The round geometry of the inserts and subsequent chip-
material was measured to be 7.1 ± 0.65 GPa. The effect of the thinning effect at the trailing edge of the cutting tool lead to

Fig. 7 Surface damage and wear

signs on the machined inconel
surface in the forms of pits and
cracks
Int J Adv Manuf Technol (2021) 112:1941–1950 1947

Fig. 8 Optical and electron

microscope images of the cross
sections of the machined surfaces
after high-speed milling with (a
and b) sharp SiAlON tools (c and
d) worn ceramic tools

minimum plastic deformation at the tertiary shear deformation

zone and consequently, a negligible alteration in the nano-
hardness of the near-surface.

3.5 Residual stress measurements

Residual stress levels on the surfaces were also measured

using an X-ray diffraction (XRD) instrument, the result of
which is listed in Table 2 for both ceramic and carbide tools
at their respective cutting parameters.
Results show that the high-speed milling operation
with SiAlON ceramic tools generates very high levels
of tensile residual stress on the machined product which
is the result of high-temperature gradients generated dur-
ing plastic deformations at high strain rates alongside
with friction between the worn cutting edge and the new-
ly formed machined surface at the tertiary shear defor-
mation zone. Low thermal conductivity of both tool and
workpiece also plays a prominent role in the cutting
temperature rise as it impairs the proper dissipation of
heat from the cutting zone. On the other hand, IN718’s
Fig. 9 Formation of a white layer on the surface machined with ceramic resistance to heat and fast-moving heat source at high
tools at high speed speeds means the damaging effect of the machining
1948 Int J Adv Manuf Technol (2021) 112:1941–1950

Fig. 10 a Nano-hardness of the machined surface after machining with axial DOC. c Typical indentation matrix on one of the samples at 1-μm
SiAlON at 900 m/min with varying axial DOC. b Nano-hardness of the mapping resolution. d Chip-thinning effect in face milling with round
machined surface after machining with WC-Co at 35 m/min with varying cutting inserts

process will be contained within a narrow band under- High tensile residual stress on the machined surface
neath the machined surface and will not penetrate deep suggests that the high-speed milling process of hardened
into the bulk of the material. In most cases, a finishing IN718 has a stronger thermal effect on the surface rather
pass can be used to remove the damaged layer. than mechanically induced stresses. In general, the nega-
tive rake angle of the inserts can create a considerable
axial mechanical load during a machining process [6].
Nevertheless, reduction in the cutting force at VC = 900
Table 2 Residual stress measurements on the workpiece surface after
machining with ceramics at dry high-speed and WC-Co at wet conditions m/min was so significant that the effect of mechanically
using sharp and worn tools induced compressive residual stresses became negligible.
Higher cutting forces at a lower speed of 500 m/min and
Tool Wear condition Normal residual stress (MPa)
shorter cutting (heating) time at a higher speed of 1300 m/
SiAlON ceramic Sharp 1635.2 ± 30.2 min suggest the generation of lower residual stresses com-
Worn 2016.6 ± 17.9 pared to optimal VC = 900 m/min. This is confirmed by
PVD-coated WC-Co Sharp 226.9 ± 34.3 XRD measurement as the residual stress levels for sharp
Worn 804.1 ± 42.6 tools at speeds of 500, 900, and 1300 m/min. The results
are presented in Table 3.
Int J Adv Manuf Technol (2021) 112:1941–1950 1949

Table 3 Sub-surface residual stress levels for sharp SiAlON tools life of sensitive engineering components, particularly
Cutting speed (mm/min) Residual stress (MPa) high-temperature aero-engine components.
3. High-speed machining with ceramic tools generates a 1–
500 1013.1 ± 19.5 2-μm white layer on the surface. This layer is very hard
900 1635.2 ± 30.2 and fine-grained and remains unetched in metallography
1300 1419.0 ± 48.8 MPa and thus appears white under the microscope. This layer is
believed to be formed following the effect of rapid
cooling from high temperatures. For the machining tests
performed in this study, the surface approached the melt-
4 Conclusions ing point of IN718 while also experiencing high mechan-
ical and tribological loads in the tool-workpiece friction
The integrity of IN718 machined surface generated by high-
zone.
speed dry milling using SiAlON ceramic tools and wet con-
4. The round geometry of the inserts, selected for their struc-
ventional milling using an industrial benchmark coated
tural strength, had a chip-thinning effect when used in the
cemented carbide tool with similar geometries were examined
face milling process. The use of round inserts in this ap-
in a set of machinability investigations, tool wear studies,
plication was found to cause minimum work-hardening
near-surface metallography methods, optical and electron mi-
on the immediate sub-layer of the machined surface, thus
croscopy imaging, EDS, roughness measurements, nano-in-
ensuring acceptable final part quality in this aspect.
dentation, and XRD. It is shown that SiAlON ceramic cutting
5. Dry high-performance milling of inconel generates ex-
tools can significantly increase the productivity of the
treme tensile residual stress on the IN718 machined sur-
manufacturing process when used at optimal cutting speeds
face, up to 2.5 times higher than when WC-Co inserts
around 900 m/min. However, reaching such cutting speeds
with similar geometry are used in wet milling at lower
generates extreme localized heat and mechanical loads that
cutting speeds. The residual stress of the surface was mea-
can potentially deteriorate the integrity of the machined sur-
sured to be more than two gigapascals on the final ma-
face. Following the observations discussed in this study, it is
chined surface. However, the low thermal conductivity of
recommended that the ceramic tools should be used only for
the workpiece material leads to a narrow heat-affected
semi-finishing or roughing applications with a few tens of
zone, thus allowing a final finishing pass using a WC-
micron stock left for removing the surface imperfections gen-
Co insert to remove the high residual stress area.
erated using the SiAlON tool by performing a subsequent
6. As for the future work, authors are investigating the ap-
finish machining operation with a sharp coated cemented car-
plication of different lubricants for reducing the excessive
bide tool.
heating and consequent damages to the tools and ma-
chined surface at high-speed milling of IN718.
1. Cutting speeds as high as 1000 m/min can be achieved
using SiAlON ceramic tools for machining of IN718m, Authors’ contributions Farhad Molaiekiya conceptualized and per-
while the recommended cutting speed for the coated car- formed the experiments, analyzed and interpreted the results, and wrote
bide tools used in common industrial applications is 35 and prepared the manuscript; Ali Khoei assisted with XRD experiments
and assisted with reviewing and editing; Maryam Aramesh assisted with
m/min. This translates to more than 4 times productivity
writing, reviewing, and editing; Stephen C. Veldhuis supervised and ad-
in terms of MRR. ministered the project.
2. The roughness of the surface produced by fresh tools is
better when cutting at high speeds with ceramics in com- Funding This research was supported by the Natural Sciences and
parison with conventional tools. Worn ceramic tools gen- Engineering Research Council of Canada (NSERC) under the
erate a rougher surface at the end of the tool life of Ra = CANRIMT Strategic Research Network Grant NETGP 479639-15.
4.5 μm compared to Ra = 2.19 μm obtained from the
cemented carbide tools at the end of life. Cutting with Compliance with ethical standards
ceramic tools at high speeds generates an excessive
Conflict of interest The authors declare that they have no conflicts of
amount of built-up edge, which intensifies with the evo- interest.
lution of tool wear. Unstable BUE and transferred layers
can detach from the tool and stick to the workpiece and
cause cracks, pits, smearing, and material pull-out signs
on the surface. Traces of silicon contamination were References
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