On high-speed turning of a third-generation gamma titanium aluminide

Gamma titanium aluminides are heat-resistant intermetallic alloys predestined to be employed in components suffering from high mechanical stresses and thermal loads. These materials are regarded as difficult to cut, so this makes process adaptation essential in order to obtain high-quality and defect-free surfaces suitable for aerospace and automotive parts. In this paper, an innovative approach for longitudinal external high-speed turning of a third-generation Ti-45Al-8Nb- 0.2C-0.2B gamma titanium aluminide is presented. The experimental campaign has been executed with different process parameters, tool geometries and lubrication conditions. The results are discussed in terms of surface roughness/integrity, chip morphology, cutting forces and tool wear. Experimental evidence showed that, due to the high cutting speed, the high temperatures reached in the shear zone improve chip formation, so a crack-free surface can be obtained. Furthermore, the use of a cryogenic lubrication system has been identified in order to reduce the huge tool wear, which represents the main drawback when machining gamma titanium aluminides under the chosen process condition

Drilling experiments on a gamma titanium aluminide obtained via electron beam melting

Gamma titanium aluminides are intermetallic structural alloys with many advantages like high temperature and oxidation resistance, low density, high specific strength, rigidity, etc. This makes them promising candidates for critical applications where both mechanical and thermal properties are required. Unfortunately, their machinability is demanding, generating low cutting life and poor surface conditions. A deeper knowledge on the machining parameters is essential for a wider application of these heat resistant light-weight alloys in aircraft and automotive industry. In this paper, the performance of uncoated carbide drills in drilling a gamma titanium aluminide was analysed. The workpiece material was obtained via electron beam melting (EBM) process, a versatile technology for additive manufacturing of complex metal parts from metal powders. EBM is highly appealing in the field of aeroengine components, and it is particularly interesting in processing gamma titanium aluminides. Cutting performances were measured in terms of tool wear, surface roughness, dimensional and geometric errors. The experimental results show strong dependence of tool wear and part quality on cutting parameters, with poor tool life compared with other work material