Local structure of metallic chips examined by X-ray microdiffraction

Abstract

Nickel-base alloys are used in high-temperature applications whenever steels or titanium alloys cannot be applied anymore. This class of alloys is furthermore used in low-temperature applications in the oil or gas industry in case the corrosion resistance of stainless steels in related liquid media is not sufficient and titanium alloys would be too expensive. Nickel-base alloys, however, due to their high strength and toughness can be machined only at low cutting speeds as otherwise poor surface quality and enhanced tool wear is observed. From all aspects influencing the machinability, the chip formation mechanism is the key factor and only a thorough understanding of this mechanism can lead to an optimisation of the cutting process.

In the current study, a detailed microstructure and phase analysis of Alloy 625 chips produced in an orthogonal cutting process at conventional cutting speeds is presented. Utilising hard monochromatic X-rays focused down to micrometre size, microstructural differences between distinct structural units of the chips, namely, the segments and shear bands, are investigated. Scanning cross sections of the chips with this small beam allowed us to determine misorientation between the segments and shear bands crystal lattices which as we found are not changing abruptly but continuously, with an absolute difference up to 10°.