Materials / Superalloys

High-Performance Superalloys (HRSA)

Superalloys are high-strength metals whose complex composition of different metals and other elements makes them suitable for use in high-temperature applications. They are also called heat-resistant alloys for this very reason. Well-known examples include Inconel 718 and Hastelloy. When it comes to superalloys such as Inconel 718, Hastelloy, and titanium, it is important to consider the significant heat build-up that occurs when working with the materials as well as the high cutting forces required to machine them. Along with this, there is also an increased risk of fire when machining titanium.

High-Performance Superalloys (HRSA) designed for extreme environments

Superalloys owe their enhanced tensile strength at high temperatures to a complex blend of base elements like iron, nickel, platinum, chromium, and cobalt. They are significantly more expensive to produce than conventional steels, which is why they are primarily used in highly demanding applications where no alternatives are available. Examples include jet engines in the aerospace industry and gas turbines in the energy sector. Titanium is also used in specialized applications like hip replacements.

Here are some popular superalloys and their machining challenges:

  • Inconel 718: A heat-resistant alloy in the ISO S group (material number 2.4668) that can withstand temperatures up to 620°C. Machining challenges include significant heat build-up, requiring tools with heat-resistant coatings, and burr formation.
  • Hastelloy C22: Part of the ISO S group (material number 2.4602), this superalloy is highly corrosion-resistant and used in the chemical, aerospace, and petrochemical industries. Machining challenges include extreme heat build-up, high cutting forces, and burr formation.
  • Titanium Ti-6Al-4V: An ISO S titanium alloy (material number 3.7165) with a high strength-to-weight ratio and excellent corrosion resistance. It is used in aerospace (compressor blades, housings, screws for jet engines) and medical (prosthetics) applications. Machining challenges include chemical affinity, high cutting forces, and burr formation.

When machining superalloys like Inconel, Hastelloy, and titanium, it is important to consider their material-specific properties. High cutting forces are required due to the alloys' composition, increasing the risk of strain hardening. Extremely sharp cutting edges are necessary, and a high amount of heat is released during machining, necessitating tools with heat-resistant coatings.

For reliable, precision machining solutions for superalloys, ZCC Cutting Tools (ZCC CT) offers a wide range of high-quality tools for turning, milling, and drilling these challenging materials.