Modern Machining of Advanced Aerospace Alloys - Enabler for Quality and Performance

Abstract

Advanced Aerospace alloys are designed to withstand high loads at extreme temperature conditions in their specific applications. These advanced alloys are more demanding in terms of machinability as their structure and material properties are focused on improved resistance to dwell crack growth, environmental damage (hot corrosion and oxidation) and creep strain, as well as higher levels of microstructure stability and high temperature yield stress. Machining of these alloys therefore focuses on high stock removal rates in roughing processes as well as in high surface finishing rates and good surface finish and surface integrity in finish machining. High performance machining methods will enable the aero engine manufacturing industry to meet increasing future requirements supported by an improved understanding of processes and process control factors. In addition to the technical challenges a number of other elements have to be considered to meet future business requirements, which include robustness of machining solutions and control of boundary conditions to be met in order to ensure acceptable surface and subsurface conditions in machining. Modern machine tool concepts, advanced machining processes and methods are key enablers to achieve overall quality and productivity goals to meet future market requirements.