Microscopic Observations on the Origin of Defects During Machining of Direct Aged (DA) Inconel 718 Superalloy

Surface quality of advanced superalloys after machining is one of the major issues in the aerospace industry because it directly affects service characteristics of the machined part. Tool life of cemented carbide inserts with the TiAlN coating during machining of direct aged DA 718 alloys under roughing and finishing conditions has been under study. The defect origin on the surface of the machined part was investigated. Metallographic observations of the DA 718 were made using optical metallography and SEM/EDS. To find out the origins of surface defect formation, the morphology of machined parts and cross sections of the machined surfaces have been investigated. Two major categories of defects were detected on the surface of the machined part: cracks and tears. The origin of the cracks on the machined surface is related to shearing of the primary complex TiC/NbC carbide revealed in a structure of DA 718 alloy. At the same time, Nb-rich regions of the primary complex carbide interact with the environment (oxygen from air) during machining with further formation of low strength oxide layer on the surface, forming tears.