Influence of tool variables on wear when milling iron aluminide alloy Fe25Al1.5Ta [at.-%

Abstract

Non-ferrous high-performance materials such as titanium- and nickel-base alloys are of great importance for the aerospace industry due to their advantageous properties. However, the high material prices of these alloys are a disadvantage. At the same time, iron aluminide alloys can feature similar mechanical and thermal properties combined with a significant economic advantage over other high-performance alloys. Thus, iron aluminides present a promising alternative to high priced non-ferrous alloys and have the potential to substitute established materials for components such as turbine blades.In aerospace part production, milling represents an important finishing process. Iron aluminides are considered difficult to cut materials. Therefore, occurring tool wear and its mechanisms are the primary issues in machining. These topics are not yet covered in depth by the prevailing knowledge base. In this paper, near-net-shape cast iron aluminide cross-samples were machined using ball end milling cutters to analyze the occurring tool wear and the performance of different milling tool systems. The results show a fundamental influence of the tungsten carbide substrate and the tool coating on tool wear when milling iron aluminide. The tools’ macro and micro geometry affect the active forces and stabilize the cutting edge. The present study provides insights about preferable tool variables that contribute to extending tool life in iron aluminide turbine blade production.