New technology enables machining of super alloys used in jet engines, nuclear reactors and space craft

A new technology has been developed that will transform the way manufacturers cut through some of the hardest materials known to engineering like Inconel 625, a nickel-based super alloy. It significantly lowers the cutting force required as well as the wear and tear of tools.

These materials, known for their high strength, versatility, excellent corrosion resistance, and employability in very high temperatures and extreme environments, are used in strategic sectors ranging from aerospace and chemical engineering to nuclear reactors as well as in power production systems.

Machining the ultra-tough super alloys has always posed a challenge. Their exceptional strength and heat resistance that make them indispensable, also make them incredibly difficult to shape and fabricate components. Traditional cutting tools often struggle, suffering rapid wear and producing inconsistent results.

Researchers at the International Advanced Research Centre for Powder Metallurgy and New Materials have developed a hybrid technique called Laser-Assisted Turning (LAT), which combines localised laser heating with mechanical cutting.

A high-power diode laser, up to 2500 watts, precisely heats the work piece just ahead of the cutting tool, inducing thermal softening in the material. This significantly reduces cutting resistance, improves chip formation and enhances tool life and machining quality.

A key innovation during the research was the integration of a Computer Numerical Control (CNC) turn-mill centre with a fibre-coupled diode laser, custom-designed adapters, and real-time monitoring tools.

This breakthrough offers a scalable, high-precision solution for industries that require the machining of difficult-to-machine materials, particularly in aerospace, power generation, and marine sectors, according to information shared by the Ministry of Science and Technology on Wednesday.

The researchers evaluated the turning of Inconel using both, uncoated tungsten carbide tools and Chromium nano-composite coated tools, known for their superior hardness, thermal stability and oxidation resistance.

When paired with LAT, these coated tools delivered outstanding performance such as, 69 percent reduction in cutting force, 46 per cent lower tool wear and 56 per cent improvement in surface finish compared to conventional methods, according to the research, which has been published in Process Mechanical Engineering and Materials Letters, a peer reviewed journal.

Tools coated with materials like tungsten carbide and chromium-based nano-composites also pave the way for next-generation turbine blades, surgical tools and high-performance automotive parts that are lighter, stronger, and more efficient.

The research insights could help in understanding tool failure modes and estimating the thermal stability and service life of the cutting tools, while also aligning with India’s strategic goals of boosting domestic manufacturing, improving energy efficiency and adopting cleaner industrial technologies, the Ministry said.