Understanding tool cutting-edge microstructure and deformation mechanism induced by adhesive wear in the turning of nickel-based superalloys

Nickel-based superalloy has great potential in the aerospace industry as key components. However, difficult-to-machine characteristics have further limited its application. Thermal-barrier coatings of the titanium-based family on carbide tools offer exceptional performance in cutting superalloys, combining high-temperature stability and remarkable toughness. This work primarily concentrates on understanding cutting-edge microstructure and deformation induced by tool adhesive wear in the turning of nickel-based superalloys with experiment and modelling. The dominant tool wear mechanisms are revealed to be adhesive wear and abrasive wear by SEM/EDS. The microstructure of the cutting-edge interface is qualitatively and quantitatively investigated by SEM/EDS and EBSD. The adhesive layer thickness at cutting edge is about 10–30 μm. The GND density of WC grains at cutting edge is 15-20 × 10¹⁴/m. The nanomechanics properties of the tool wear interface were quantitatively evaluated by nanoindentation. The average hardness of WC and Ni-superalloy at cutting-edge interface is evaluated to be 15–19 GPa and 6.2–6.5 GPa, respectively. Further, the underlying deformation mechanisms induced by tool wear behaviours are revealed through the transient heat conduction model and cutting-edge stress distribution model. This research offers a framework and mechanism for the cutting tool wear surface/interface characteristics targeted to the difficult-to-cut superalloy materials. © 2024 Elsevier B.V