Performance of advanced ceramic round tools when turning Inconel 718

Nickel-based superalloys, like Inconel 718, are very attractive metals for aerospace applications due to their excellent mechanical properties and thermal stability. However, these materials pose a significant challenge to the metal machining industry due to their very low machinability, especially in terms of reduced tool life because of the high heat generated during cutting. Nevertheless, it can be improved using high-performing tools that retain their hardness when exposed to high temperatures, such as ceramic tools. In this context, the study aims to compare the performance of two advanced ceramic tools, namely an alumina ceramic tool reinforced with SiC whiskers and a Bidemics™ one, when turning Inconel 718 at different cutting speeds, using as a baseline a conventional coated cemented carbide tool. First, the three inserts were characterized in terms of topography, thermal conductivity, and hot hardness to fully understand their operational behavior. Then, turning trials were conducted showing that both the ceramic tools outperform the coated carbide one in terms of tool life, with Bidemics™ demonstrating the best performance among all. This can be ascribed to its very high hardness maintained even at high temperatures, as well as its moderate thermal conductivity.