Machining of WAAM-cladded Inconel 625 for energy components: influence of cutting conditions and tool geometry

Abstract Effectivity and service life of energy components play very significant role in energy industry. Therefore, the Inconel cladding is applied to increase service life of metal tubes used in the incineration kettles. This study aims to examine the effect of cutting parameters and inserts geometry when turning of cladded Inconel 625 layer. The cladded Inconel 625 material was prepared by wire arc additive manufacturing method, which is employed as the effective cladding method of Inconel 625 on the metal tube. Testing was carried out by turning of spiral cladded Inconel 625 under different cutting conditions with different tool geometry. Cutting forces, surface roughness, tool life, chip formation and surface texture were investigated. The results showed that machining parameters have a significant effect on machinability, surface quality, and tool wear. The lower cutting conditions exhibited lower cutting forces and surface roughness compared to the tests carried out under the higher cutting conditions. The lower cutting speed resulted in lower tool wear monitored on the cutting inserts. At cutting speed of 15 m.min − 1 and feed 0.1 mm, the lamellar chip was formed with distinguishable shearing zones. The simulation of chip formation was performed using Finite element method analysis. The simulation revealed the lamellar chip formation when using the higher cutting speed. The result of the work can be effectively used when machining Inconel cladded material used in energy industry to ensure higher efficiency of whole components.