Short answer

When designing with Inconel 718 produced via WAAM, anticipate and plan for more intensive post-machining operations to achieve the required surface integrity.

Field
Final Production
Source
Journal of Manufacturing and Materials Processing (2023)
Method
Comparative experimental analysis
Evidence
Strong effect

Additive manufactured Inconel 718 exhibits less stable machining characteristics and poorer surface quality post-machining than conventionally rolled Inconel 718 due to its inherent microstructural and surface irregularities. This final production research insight is drawn from a 2023 study published in Journal of Manufacturing and Materials Processing. Using Comparative experimental analysis, researchers explored how this design variable affects real-world outcomes. The key design takeaway: When designing with Inconel 718 produced via WAAM, anticipate and plan for more intensive post-machining operations to achieve the required surface integrity.

Study
Final ProductionRecentStrong effect

WAAM Inconel 718 requires enhanced post-machining for superior surface finish compared to rolled counterparts.

Additive manufactured Inconel 718 exhibits less stable machining characteristics and poorer surface quality post-machining than conventionally rolled Inconel 718 due to its inherent microstructural and surface irregularities.

Journal of Manufacturing and Materials Processing · 2023

01

Key Findings

  • 01Rolled Inconel 718 samples demonstrated greater cutting process stability with less variability in cutting forces compared to WAAM samples.
  • 02WAAM Inconel 718 samples exhibited poorer surface quality after the machining process.
02

Application

Design takeaway

When designing with Inconel 718 produced via WAAM, anticipate and plan for more intensive post-machining operations to achieve the required surface integrity.

How to apply

When evaluating the feasibility of using WAAM for Inconel 718 parts, incorporate a detailed assessment of the post-machining effort and cost required to meet surface finish specifications.

Project actions

  • 01When comparing manufacturing methods, consider not just the primary fabrication but also the necessary secondary operations.
  • 02Investigate how material microstructure and anisotropy affect machining performance.
03

Method & Evidence

AimTo compare the machinability and resulting surface quality of Inconel 718 produced via Wire and Arc Additive Manufacturing (WAAM) against conventionally rolled Inconel 718 (AMS 5662).
MethodComparative experimental analysis
ProcedureWall-shaped samples of Inconel 718 were fabricated using WAAM and a rolled bar of Inconel 718 was used as a control. Both material types were subjected to milling operations using a conventional two-flute cutting tool over multiple passes at different heights. Cutting forces were monitored, and surface quality was assessed post-machining.
ContextAdditive Manufacturing and Machining of High-Performance Alloys

Variables

IVManufacturing method (WAAM vs. Rolled Bar)
DVCutting force variability, Surface roughness
CVMaterial (Inconel 718), Cutting tool type, Number of passes, Machining depth
04

Strengths & Limitations

Strengths

  • +Direct comparison between an additive and a conventional manufacturing route for the same alloy.
  • +Focus on a critical post-processing step (machining) that directly impacts product quality.

Limitations

The specific WAAM process parameters and the chosen machining strategy might not be representative of all possible scenarios.

Reliability & validity

The study's validity is supported by a direct comparison of two distinct manufacturing methods for the same material. Reliability would depend on the repeatability of the WAAM process and the precision of the machining tests.

Think critically

To what extent can advancements in WAAM process control and post-processing techniques mitigate the observed differences in machinability and surface quality compared to traditional methods?

05

Design Principles

"The manufacturability of an additively manufactured component is influenced by its inherent process characteristics, necessitating tailored post-processing strategies."

As additive manufacturing techniques like WAAM become more prevalent for high-performance alloys, understanding their post-processing requirements is crucial. Designers and manufacturing engineers must account for the additional steps and potential challenges in achieving desired surface finishes and dimensional accuracy for critical applications.

06

What This Means for Your Design

Parts made using 3D printing (WAAM) with metal like Inconel 718 are harder to machine smoothly than parts made from solid metal bars, leading to a rougher surface finish.

How to use in your project

  • 1.Use this study to justify the need for post-processing in your design project if you are considering additive manufacturing for metal components.
  • 2.Reference this paper when discussing the trade-offs between different manufacturing routes and their impact on final product quality.
07

Add to My Project

08

Quick Cite

Paragraph starter

The machinability of Inconel 718 produced via Wire and Arc Additive Manufacturing (WAAM) presents distinct challenges compared to its conventionally rolled counterpart. Research indicates that WAAM components exhibit less stable machining processes and a poorer surface finish post-machining, attributed to factors such as uneven surfaces, dendritic microstructures, and anisotropy inherent in the additive process. This necessitates a thorough consideration of enhanced post-processing steps in design projects utilizing WAAM for critical applications.

09

Source

Journal of Manufacturing and Materials Processing

Analysis of Machinability on Properties of Inconel 718 Wire and Arc Additive Manufacturing Products

journal · 2023

View source

Questions About This Research

What does the research say about waam inconel 718 requires enhanced post-machining for superior surface finish compared to rolled counterparts?
When designing with Inconel 718 produced via WAAM, anticipate and plan for more intensive post-machining operations to achieve the required surface integrity. Evidence: Journal of Manufacturing and Materials Processing (2023).
Why does "WAAM Inconel 718 requires enhanced post-machining for superior surface finish compared to rolled counterparts." matter for design?
As additive manufacturing techniques like WAAM become more prevalent for high-performance alloys, understanding their post-processing requirements is crucial. Designers and manufacturing engineers must account for the additional steps and potential challenges in achieving desired surface finishes and dimensional accuracy for critical applications.
How can designers apply this research?
When designing with Inconel 718 produced via WAAM, anticipate and plan for more intensive post-machining operations to achieve the required surface integrity.
What were the main findings?
Rolled Inconel 718 samples demonstrated greater cutting process stability with less variability in cutting forces compared to WAAM samples.. WAAM Inconel 718 samples exhibited poorer surface quality after the machining process.
What research method was used?
Comparative experimental analysis.
How strong is the evidence?
Evidence strength is rated Strong effect, based on a 2023 journal from Journal of Manufacturing and Materials Processing.
What should I do differently in my next project?
When evaluating the feasibility of using WAAM for Inconel 718 parts, incorporate a detailed assessment of the post-machining effort and cost required to meet surface finish specifications.
What are the limitations?
The study focused on specific milling parameters and a single type of cutting tool; other machining processes or tool geometries might yield different results. The specific WAAM parameters used could also influence the outcome.