CNC Machining Inconel: An Ultimate Guide
Inconel is a super alloy that is resistant to high temperatures, corrosion, and fatigue. Its unique properties make it an excellent choice for aerospace, automotive, and chemical. However, due to its high hardness, Inconel is challenging to process. In this article, we will look at the advantages, challenges, surface treatment, and tips you need to know to complete Inconel machining.
A Brief History of CNC Machining Inconel
The machining process of Inconel started in the 1970s and 1980s as Inconel was always known for its excellent corrosion resistance and high-temperature handling. Hence, Inconel made an important space in the industrial and aerospace applications.
The traditional methods were not capable of machining Inconel due to its hardness, however, the evolution of CNC technology improved the Inconel efficiency and precision of the components. Moreover, CNC machining also made room for Inconel components which have complex geometries, and the process made it easier to work with such challenging materials.
In recent years, the advancement in CNC technology has helped with advanced tools for cutting, cooling systems, and high-speed spindles. These factors have contributed to the productivity and performance of the process of CNC machining Inconel.
Propiedades del Inconel
Inconel is known for its seamless properties and due to this it suits various demanding applications, some of these properties of Inconel are discussed below:
- Inconel maintains its structural integrity and strength at high temperatures which makes it suitable for use in environments where high temperature is a part of surroundings like gas turbines.
- The Inconel alloy comprises a high content of chromium which makes it resistant against corrosion and oxidation offering suitability for marine and chemical processing environments.
- Inconel exhibits seamless durability and mechanical strength which makes it suitable for high-stress conditions.
- It is also very much suitable for applications consisting of fluctuating temperatures due to its thermal stability.
Grades of Inconel
Inconel alloy comprises multiple grades and each type of grade has different properties, some of the commonly used grades of Inconel are given below:
Inconel 625
Inconel 625 offers seamless strength and corrosion resistance and is suitable for working in harsh environments. It can even resist wear and tear when exposed to high-pressure or moisture-oriented environments. It is commonly used in marine and aerospace components due to its properties.
Inconel 718
Inconel 718 is known for its exemplary performance in extreme environments, it has a high tensile strength and offers excellent resistance to work-hardening. It is highly compatible with the CNC machining process and has the capability to perform in extreme environments. It is suitable for use in hydrogen generation systems and aerospace components due to its integrity under tough conditions.
Inconel 600
Inconel 600 offers resistance against corrosion, it has a high content of nickel which offers durability and protects from stress-corrosion cracking. It is used in the thermal processing and chemical industry for its resistance against corrosive material and also it can handle high temperatures.
Benefits of CNC Machining Inconel
There are multiple benefits of CNC machining inconel and some of these are given below:
Consistency and Precision
CNC machining is a highly precise and repeatable process that helps to manufacture complex and intricate inconel components that have tight tolerance. It ensures quality and performance through multiple parts.
Efficient Mechanism
The advanced CNC technology helps to improve machining efficiency by automating the processes and reducing the need for manual labor hence, it proves to be a highly suitable process for large volume manufacturing with faster turnaround time.
Geometrías complejas
CNC machines have the capability of handling intricate and complex designs which helps to achieve components that have complex geometries in industries like aerospace and automobile.
Reduction in Tool Wear
The advanced CNC machines today comprise high-performing cutting tools and advanced cooling systems, such machines help to manage heat during the machining process. Inconel being a hard and abrasive alloy proves to be suitable to work with CNC machining as the cooling system helps to extend the life of tools reducing tool wear.
Mejor acabado superficial
CNC machining offers seamless surface finishes which is very important for Inconel components which need aesthetic appearance and tight tolerance. It is highly beneficial for such applications where structural integrity and surface smoothness are important.
Challenges of CNC Machining Inconel
There are multiple benefits for machining Inconel components but at the same time, there are certain challenges that are faced during the machining of Inconel components. Some of these challenges are given below.
Wear and Tear of Tools
The hardness of Inconel leads to increased tool wear which causes the cost of maintenance to increase because tools need proper maintenance for efficient cutting when worn out.
High Heat Generation
The process of CNC machining Inconel generates a lot of heat and this causes thermal distortion of the workpiece and also leads to increased tool wear. To mitigate this issue the need for cooling systems is vital.
Low Machining Speed
The cutting speed for machining Inconel is generally kept low when compared to the softer materials. This leads to increased machining time and also increases the cost of manufacturing.
Lack of Surface Finish
The surface finishing for an Inconel component could be hard to achieve during machining because Inconel is a tough material and it needs highly advanced machining techniques with precise control.
Surface Finishes for CNC Machined Inconel Parts
After the process of Inconel machining, some components may need further surface finishing for the Inconel components, some of the surface finishing options are as follows:
Grinding: The process of surface grinding helps to add smoothness to the surface of Inconel components as it removes the top layer of material and also reduces the tool marks. The process of grinding helps achieve better dimensional accuracy. Inconel components used in the automobile and aerospace industry are mostly subjected to grinding.
Pulido: Applications that require a shiny surface for the Inconel components are subjected to polishing after the machining process. In the process of polishing, abrasive compounds and materials are used to achieve a mirror-like surface finish and appearance. Decorative items and high-end consumer products that need appealing surfaces are subjected to polishing.
Blasting: Sandblasting and bead blasting are the two types of surface finishing processes that help to create a textured finish on the Inconel component. Abrasive particles are released at a high speed on the surface which helps to create a textured finish. It is commonly used in architectural and industrial applications of Inconel components.
Plating and Coating: The application of coating and plating on the Inconel components either in the form of nickel or chromium helps enhance the surface finish and also makes the components more corrosion-resistant. The process of coating and plating is commonly opted for the finishing of Inconel components that are used in aerospace, marine, and automobile applications.
Applications of Inconel CNC Machining
The application of CNC machined Inconel components is observed in various industries and some of these are given below:
Aeroespacial
Inconel is opted for the aerospace industry to manufacture parts for jet engines and gas turbines because the Inconel material can handle extreme conditions. These components are very crucial for the performance and safety of the aircraft as they offer unmatchable strength and are suitable for corrosive and high-temperature environments.
Automoción
The automobile industry requires components that are heat-resistant, corrosion-resistant, and strength-oriented, and Inconel components offer all these properties. Hence, Inconel 625 and 718 machined parts are widely popular in manufacturing turbocharger rotors and exhaust systems of vehicles as these grades can handle high stress and temperature.
Petróleo y gas
The oil and gas industry requires components that can withstand harsh surroundings. Hence, Inconel machined components work perfectly in this sector. Inconel machined components are equipped with tight tolerance and they are highly durable. In the oil and gas sector, it helps to create surface equipment and downhole tools.
Tips for CNC Machining Inconel
Inconel is a challenging material but when machined with some important tips you can achieve some high quality and precise components. Some of the important tips for CNC machining Inconel are as follows:
- It is very important to choose the right cutting tools which are specifically designed to machine material like Inconel to help with cutting and shaping efficiently and this comprises carbide tools.
- During the process of CNC machining, a lot of heat is generated and there is a need to use plenty of coolant so that the temperature remains low and thermal damage is avoided.
- Optimal adjustment of machining parameters is crucial to achieve the right cut, parameters like feed rate, depth, and cutting speed need optimized adjustment.
- The setup of machining of Inconel should be rigid so that deflection can be minimized and high dimensional accuracy can be achieved.
- Post-machining procedures are important for Inconel components to achieve the required tolerance.
Conclusión
Inconel is a versatile yet challenging material when it comes to the machining process. Hence, the guide above features detailed insight that will help you efficiently work with this material and understand everything about CNC machining Inconel.
CNC Machining Inconel at DEK
If you are looking for customized CNC-machined Inconel components for your applications, you can get in touch with DEK. We offer you Inconel components with tight tolerance, precision, and excellent finishing which are capable of adding functionality to your application requirements. So, contact us today and specify your requirements.
Preguntas frecuentes
Is Inconel difficult to machine?
Yes, due to its high strength and toughness, Inconel offers a challenging material when it comes to machining and it needs specialized tools to achieve desired results.
Is Inconel harder to machine than titanium?
Yes, Inconel is harder to machine than titanium. Inconel has high work-hardening rates and causes high tool wear which is not the case with titanium.
What is the best way to cut Inconel?
The best way to cut Inconel is using carbide tools or high-speed steel tools which comprise a strong cutting edge. Also, high feed rates and low cutting speed help to reduce the work-hardening of Inconel.
