Optimizing Machining of High-Temperature Alloys in Aerospace

Optimizing machining of high-temperature alloys in aerospace

January 6, 2025
By Sandvik Coromant, for the Blue Print

As the aerospace industry pushes the limits of engine and component performance, manufacturers increasingly rely on high-refractory superalloy (HRSA) materials like Inconel and Hastelloy. These alloys offer exceptional strength and heat resistance – critical properties for components that operate in the extreme conditions of modern jet engines.

Machining HRSA’s, however, comes with challenges. Their hardness, abrasiveness, and tendency to rapidly work harden make them notoriously difficult to machine efficiently and economically. Shops risk excessive tool wear, poor surface finish, dimensional inaccuracy, and reduced productivity.

To help aerospace manufacturers overcome the obstacles of HRSA machining, here are some essential tips and strategies to consider.

Tool selection

Selecting the right cutting tools for HRSA materials is essential. High-strength inserts with heat-resistant substrate and specialized coating designed specifically for machining nickel and cobalt-based superalloys provide significantly longer tool life compared to standard carbide. Investing in the right tooling upfront ensures cost control and consistent quality.

Optimize cutting parameters

Unlike traditional steel alloys, HRSA materials perform best with lower cutting speeds, increased feed rates, and shallow depths of cut. Experimenting with these parameters to find the ideal balance can go a long way toward extending tool life, improving surface finish, and boosting productivity.

Leverage unique toolpath strategies

Innovative toolpath programming is critical for machining HRSAs. Techniques like Dynamic milling —which uses a high feed rate, small radial and large axial engagement —can help reduce cutting forces and heat buildup. Similarly, the use of multiple cutting edges within a single toolpath, along with accurate tool tracking and compensation, can enable higher metal removal rates.

Optimize coolant delivery

Effective coolant management is critical for HRSA machining. High-pressure, high-volume coolant directed at the cutting zone is essential to reduce temperatures and flush away abrasive particles. Additionally, selecting the right coolant type – water-based, oil-based, or synthetic – can also greatly impact on tool life and surface quality.

By applying these principles, aerospace manufacturers can dramatically improve their machining of HRSA materials, boosting productivity, lowering costs, and delivering superior component quality. While strategies will vary by alloy, part geometry, and production environment, a data driven approach to HRSA machining can pay huge dividends.

Content originally from Sandvik Coromant. Reused here with permission.