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Heat-treatment effect on CNC turning of INCOLOY 800H superalloy

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DOI: 10.1080/10426914.2018.1424910

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 Materials and Manufacturing Processes

ISSN: 1042-6914 (Print) 1532-2475 (Online) Journal homepage: http://www.tandfonline.com/loi/lmmp20

Heat treatment effect on CNC turning of Incoloy

800H superalloy

A. Palanisamy, T. Selvaraj & S. Sivasankaran

To cite this article: A. Palanisamy, T. Selvaraj & S. Sivasankaran (2018) Heat treatment effect
on CNC turning of Incoloy 800H superalloy, Materials and Manufacturing Processes, 33:14,
1594-1601, DOI: 10.1080/10426914.2018.1424910

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MATERIALS AND MANUFACTURING PROCESSES
2018, VOL. 33, NO. 14, 1594–1601
https://doi.org/10.1080/10426914.2018.1424910

none defined

Heat treatment effect on CNC turning of Incoloy 800H superalloy

A. Palanisamya, T. Selvaraja, and S. Sivasankaranb
a
Department of Production Engineering, National Institute of Technology, Tiruchirappalli, Tamil Nadu, India; bDepartment of Mechanical Engineering,
College of Engineering, Qassim University, Buraidah, Saudi Arabia

ABSTRACT ARTICLE HISTORY

Nuclear power plant components, high-temperature furnace, and most of the nuclear reactors are in Received 2 September 2017
need of high creep rupture which can be attained by Incoloy 800H superalloy. Based on this, the present Accepted 20 December 2017
research work is aimed to relate the microstructure, mechanical, and machinability of Incoloy 800H in KEYWORDS
various conditions, namely, solution treated, heat-treated with air cooling, and heat-treated with furnace Compression; cutting; force;
cooling. The samples were initially heated till 975°C after solution treated and then subjected to the fractography; heat; Incoloy;
aforesaid heat treatments. The optical microstructures revealed that the fine grains’ structure was microstructure; roughness;
obtained in the air-cooled sample, whereas coarse grain structure was obtained in a furnace-cooled surface; treatment; turning
sample. The heat-treated samples were machined using CNC dry turning process and the machining
parameter effects on the machinability aspects were studied, investigated, and reported. Experimental
investigations explained clearly that the machinability aspects were significantly influenced by the
cooling medium. Furnace-cooled sample had shown improvement in mechanical and machinability
performances.

Introduction high-speed steels, white cast irons, cobalt and molybdenum

alloys, Inconel, Incoloy, and Hastelloy are the examples of
In the 1950s Incoloy 800H superalloy was introduced into
hardened materials.[9–14] Recently, many researchers have
the marketplace; then the application of Incoloy 800H into
focused on machining of hard materials through turning,[3]
pressure vessels were permitted by Boiler and Pressure Vessel
milling,[4] and grinding.[5] Dry machining process has been
Committee run by ASME in the year of 1963. Incoloy 800H is
used recently when compared to wet machining process to
an iron-based austenitic alloy. Mostly, the crystalline size of
protect the environment and cost.[15–18] However, the selec-
commercially available Incoloy 800H is greater than ∼75 µm.
tion of the type of a machining would mainly depend on
The strength of this alloy can be enhanced by the solid
expected quality of the product as per customer expectation,
solution strengthening mechanisms and further, the incorpor-
its applications, and hardness of work material.[19] From the
ation of titanium nitrides (TiN) and titanium carbides (TiC) as
existing literature, it was found that there is no note of work
dispersions would multiply its strength. The major features of
available on machinability study correlated with heat treat-
this Incoloy 800H are more in creep strength and high value
ment of Incoloy 800H during dry machining process. There-
of corrosion resistance at elevated temperature. Due to this,
fore, the present experimental work is aimed to examine the
nuclear parts, high-temperature pressure vessels, furnace parts,
effect of heat treatment and the process parameters on
electrical casings, furnace cracker tubes, pigtails, and petro-
machinability of Incoloy 800H using uncoated tungsten
chemical industrial parts are usually made up of this Incoloy
carbide inserts in computer numerical controlled dry turning
800H superalloy.[1–4] The water-cooled reactor of nuclear
operations. In addition, the objectives of the present works
plant Generation IV is completely made up of Incoloy 800H.
are to compare the machinability of heat-treated samples with
This alloy is possessing high oxidization resistance due to
the as-received sample of Incoloy 800H and to evaluate the
the presence of chromium and nickel contents. In addition,
cutting force and surface roughness.
the nickel would stabilize the protective oxides which are
produced by the chromium over the alloy which retains high
Materials and Methods
temperature.[2–8] Incoloy 800H is “difficult-to-cut materials”
because of remarkable features, namely, lower in thermal The chemical composition of as-received (AR) forged rod of
conductivity, the existence of carbide particles, rapid work Incoloy 800H superalloy is listed in Table 1. The specification
hardening, attraction to tool material (through reaction), etc. of the as-received rod was 25 mm in diameter and 125 mm in
makes it not easy to machine. Hardened materials are usually length. The as-received forged rods were solution heat-treated
having the hardness range between 45 and 65 HRC.[5] Various in which the rods were heated with the heating rate of
tool steels, heat-treatable steels, hardened steels, bearing steels, 40–1075°C for 60 min in an electric induction furnace with

CONTACT S. Sivasankaran sivasankarangs1979@gmail.com; sivasankaran@qec.edu.sa; s.udayar@qu.edu.sa Department of Mechanical Engineering,

College of Engineering, Qassim University, Buraydah 51452, Saudi Arabia.
Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/lmmp.
© 2018 Taylor & Francis
 MATERIALS AND MANUFACTURING PROCESSES 1595

Table 1. Chemical composition of Incoloy 800H (wt%).
C Mo P S Si Cr Ni Ti Al Cu
0.069 0.76 0.014 0.001 0.13 20.42 31.59 0.57 0.50 0.42 45.562
the capacity of 1300°C and then the rods were water quenched.
After solution heat treatment, all the samples were further
heat-treated at 975°C for 60 min using the same heating rate
of 40°C. Then, some samples were cooled in the air called
air-cooled (AC) samples and some samples were cooled in
the furnace itself called furnace-cooled (FC) samples. The
phase diagram and the heat treatment process for the Incoloy
800H superalloys used in the present experimental work as a
schematic are shown in Fig. 1(a). To examine the compressive
strength of the samples under different conditions, the sample
size of 6 mm in diameter with a height of 9 mm (aspect ratio
1.5 as per ASTM E9 standard) was prepared carefully. The
servo-controlled Tinius Olsen H50KL universal testing
machine was used for the compression test at a strain rate of
1 mm/min. During compression test, 30% set height reduction
was used in all the samples. The microstructures of the as-
received forged rod, heat-treated samples before compression,
and heat-treated samples after compression were taken using
Olympus optical microscope. The appropriate metallographic
procedure was used for the sample preparations. The forma-
tion of titanium carbides, chromium carbides, and fractured
surfaces were examined using Hitachi S-3000H scanning elec-
tron microscope. As-received forged samples and heat-treated
samples were machined using LEADWELL CNC T5 turning
center under dry environment. The capacity of the machine
is 4500 rpm with 7.5 kW power. Figure 1(b) shows the macro-
graph of turning experimental setup and the inset of Fig. 1(b)
Table 2. Tool geometry of uncoated tungsten carbide insert.
Fe Insert nomenclature Values
Clearance angle 5°
Side rake angle 6°
Inclination angle 6°
Major cutting edge angle or approach angle 95°
Included angle or point angle 80°
Nose radius 0.8 mm
Figure 2. (a) Photograph and tool geometry of cutting insert of CNMA 120408
used during turning.
shows the Incoloy 800H rod held in the machine. During
turning, the length to diameter ratio of 2 (L/D ¼ 50/25) was
used in which 50 mm workpiece length was outside of the
chuck, whereas 75 mm workpiece length was inside of the
chuck. The machining length of 40 mm was used to avoid
undesirable deflection, tool vibration, and chattering.[20] Three
samples have been used for each experiment with a new sharp
cutting edge and the average values of the responses were
taken for investigation. The turning process was performed
using ISO K20 CNMA 120408-THM (WIDIA-India) uncoated
tungsten carbide tool. Table 2 and Fig. 2 describe the tool
geometry of the insert. In the present investigation, two
important cutting parameters such as cutting speed (35, 45,
and 55 m/min) and the feed rate (0.02, 04, and 0.06 mm/rev)
were varied as mentioned in Table 3, whereas the depth of
cut was maintained by 0.5 mm. Here, according to Special
Metals Corporation, USA, Sandmeyer Steel Company, USA,
and the Incoloy 800 H alloy supplier, tool’s catalog and
previous literature,[21,22] the machining parameters were
selected. Further, lowest levels of cutting speed, feed rate,
and depth of cut were chosen to avoid the undesirable work
deflection, tool vibration, and chattering. In addition, based
on some authors of previous work[23,24] and to have an
improved surface finish, low-level range values for feed rate
and depth of cut were used and based on the present investi-
gation, we can precisely select the optimum cutting conditions.

Table 3. Surface roughness Ra (µm) of the machined samples.

Turning parameters Surface roughness (Ra), µm
Ex. No. Vc, m/min f, mm/rev d, mm AR AC FC
1 35 0.02 0.5 1.14 1.69 0.67
2 35 0.04 0.5 1.19 1.72 0.78
3 35 0.06 0.5 1.66 2.08 1.03
4 45 0.02 0.5 1.05 1.46 0.44
5 45 0.04 0.5 1.10 1.51 0.58
6 45 0.06 0.5 1.23 1.54 0.45
7 55 0.02 0.5 0.82 1.30 0.30
Figure 1. (a) Phase diagram and heat treatment process of Incoloy 800H used 8 55 0.04 0.5 1.07 1.34 0.34
in the experiments, (b) experimental setup in LEADWELL CNC Turning Centre. 9 55 0.06 0.5 1.16 1.43 0.36
1596 A. PALANISAMY ET AL.

Table 4. Cutting force components [feed force (Fx), thrust force (Fy), and cutting force (Fz)], N.
Machining parameters Feed force (Fx), N Thrust force (Fy), N Cutting force (Fz), N
Ex. No. Vc, m/min f, mm/rev d, mm AR AC FC AR AC FC AR AC FC
1 35 0.02 0.5 83.74 104.29 72.09 92.71 116.22 81.06 166.69 168.78 161.62
2 35 0.04 0.5 87.77 106.42 83.89 98.74 121.48 92.84 215.30 225.06 169.62
3 35 0.06 0.5 93.14 114.85 87.07 102.11 138.81 100.09 224.85 312.01 201.29
4 45 0.02 0.5 64.25 98.4 60.25 73.24 106.87 71.63 155.64 160.20 124.08
5 45 0.04 0.5 79.52 95.84 67.37 91.48 109.8 78.38 172.00 220.07 151.92
6 45 0.06 0.5 84.49 100.23 77.01 99.57 115.08 93.01 212.12 255.07 183.78
7 55 0.02 0.5 62.42 70.47 59.24 69.2 83.77 65.23 106.99 148.99 101.38
8 55 0.04 0.5 64.32 76.84 61.65 76.2 91.67 71.69 160.95 206.80 120.30
9 55 0.06 0.5 70.74 81.36 65.24 80.71 95.89 76.94 188.90 226.81 134.80
Vc-cutting speed; f-feed rate; d-depth of cut; AR-As-received; AC-Air-cooled; FC-Furnace cooled

Moreover, the cutting speed range of 10–30 m/min is best
suitable to turn nickel-based superalloys.[25] The exceeding
of cutting speed above 40 m/min would represent high-speed
machining for nickel-based alloys[25] and hence the cutting
speed range of 35–55 m/min was used in this research. Nine
turning experiments were conducted in each of AR, AC, and
FC samples. Moreover, replications are needed to establish
repeatability and authenticity of the data obtained during the
experiment, so that the number of replications used in this
experiments is 3 and average values have been reported.
Further, the cutting force components (Table 4, Fx, Fy, and
Fz) and the surface roughness (Ra) were measured as
responses. These responses would mainly influence the quality
of finished products after metal cutting and hence the atten-
tion was focused on the present research work. Piezoelectric
dynamometer coupled with a charge amplifier and data acqui-
sition system (KISTLER type 9257B) was used to measure the
cutting force components [Fig. 1(b)]. KISTLER dynoware
software was used to interpret the results. The surface rough-
ness (Ra) was also measured in the turned workpiece using
Mitutoyo surf test SJ-310 and 3D surface profiles were taken
using the high-resolution white light interferometer. Table 3
illustrates the measured experimental results.
Results and Discussion
The optical microstructures of Incoloy 800H superalloys of
as-received (AR) and heat-treated under different conditions
are shown in Fig. 3(a–c). The microstructure of as-received
forged sample [Fig. 3(a)] was exhibited austenite equiaxed
grains, ferrite grain boundaries with ferrite stringers. The pres-
ence of ferrite stringers would enhance the strength of the
alloy due to which it would be very difficult to machine and
to use the alloy as-forged condition which needs heat treat-
ment. Based on several optical images, the observed average
grain size of the as-received forged sample was 182 µm.
Figure 3(b) and (c) shows the microstructures of air-cooled
and furnace-cooled samples, respectively. The air-cooled sam-
ple was exhibited somewhat fine grains [Fig. 3(b)] when com-
pared to other two conditions [Fig. 3(a) and (c)]. The
measured average grain size for the air-cooled sample was
around 110 µm. The formation of fine grains in the air-cooled
sample was attributed to considerable fast cooling rate
occurred in the air medium and formed precipitates after
heat treatment might have pinned down the grain growth.
In general, more amount of chromium carbides and a small
amount of titanium carbides as precipitate particles are usually
formed during heat treatment of Incoloy 800H.[9,20] The
formed quantity of precipitate particles would mainly depend
on temperature and time. However, the variation of precipitate
particles (both amount and size) with the aging time is not the
main objective of the present work. The combination of coarse
grains (∼75%) and fine grains (∼25%) was observed in the fur-
nace-cooled samples [Figure 3(c)]. The observed average grain
size of the furnace-cooled sample was around 342 µm. The
grain coarsening of furnace sample was attributed to slow
cooling rate started from high temperature (975°C) which
led to attain the room temperature slowly eventually grain
growth would occur. The formed fine grains in the furnace-
cooled sample were attributed to pinning of grain growth by
the precipitate particles.[18] Some twinning lines were observed
in both the heat-treated samples [Fig. 3(b) and (c)]. To
confirm the presence of formed precipitate particles after heat
treatment, SEM micrograph of heat-treated furnace-cooled
sample is shown in Fig. 2(d) which was taken at high
magnification. The corresponding EDAX spectrum is shown
in Fig. 3(e) which demonstrates the presence of more amount
of carbon, titanium, and chromium elements when compared
to the as-received chemical composition as mentioned in
Table 1. It is to be noted here that the amount of titanium
was lower than chromium which means more amount of
chromium carbides was expected to be formed when
compared to titanium carbides.[11] The observed average size
of the precipitate was around 450 nm which was expected to
enhance the machinability and work hardening.
The variation of engineering compressive stress and
compressive strain curves for as-received (AR), air-cooled
(AC), and furnace-cooled (FC) samples are shown in Fig. 4.
The calculated compressive yield strength at 0.2% strain was
472, 493, and 440 MPa for AR, AC, and FC samples, respect-
ively. It was observed here that compressive yield strength of
AC sample was exhibited more value which was 4.5% more
than the as-received sample and 12% more than furnace-
cooled sample. The higher value of compressive yield strength
for AC sample was attributed to the presence of fine grains,
precipitates, and strain fields in the grains. Further, the
compressive yield strength for FC sample was around 7.2%
lower when compared to AR sample. This result was expected
to the presence of coarse grains eventually it would soft the
matrix. The grain coarsening would occur in the furnace
cooled sample because of the slow cooling rate occur in the
furnace which meant the sample would take more time to
 MATERIALS AND MANUFACTURING PROCESSES 1597

Figure 3. Microstructures of Incoloy 800 H superalloy under different heat-treated conditions: (a) optical microstructures (OM) of as-received (AR); (b) OM of air
cooled (AC); (c) OM of furnace cooled (FC); (d) SEM of FC; (e) EDAX of (d).

reach the room temperature. However, the air-cooled sample more in yield strength. Moreover, the heat-treated samples had
would take considerable fast cooling which avoids grain shown more work hardening rate when compared to AR sam-
coarsening during heat treatment and hence it usually exhibits ple for the same 30% set height reduction. The microstructures

Figure 4. Engineering compressive stress and compressive strain curve of Incoloy 800H superalloy of as-received, air-cooled, and furnace-cooled conditions
(corresponding deformed microstructures, samples of un-deformed and deformed).
1598 A. PALANISAMY ET AL.
of deformed samples clearly demonstrated (Fig. 4) that more
elongated with almost equiaxed grains were observed in both
heat-treated samples when compared to AR sample. The
formed nanoprecipitates (∼450 nm) were expected to enhance
more strain hardening rate in the heat-treated samples.
Further, the AC sample of the compressive stress–strain curve
was shifted up (Fig. 4) due to the presence of fine grains in the
matrix and more amount of strain fields. The compressive
stress–strain curve for FC sample was shifted down when
compared to other two conditions. This was expected to the
existing of coarse grains in the matrix and lower amount of
strain fields.[26]
To examine the fracture analysis on the deformed samples
at room temperature, the deformed samples were pierced
lengthways which were parallel to the applied load
direction.[27] Figure 5 shows the SEM fractography of all the
three samples which are processed under different conditions.
The fracture surface of as-received forged condition [Fig. 5(a)]
shows dimples, craters, and crocodile patterns. The presence
of dimples would associate with the ductility, whereas the
presence of more craters and crocodile patterns would associ-
ate with the brittleness nature. The observed crocodile patterns
and more craters in the as-received forged sample were
attributed to the ferrite stringers in the matrix. Deep dimples,
the large crater, flat surface-fractured zone, and voids were
observed in the air-cooled sample [Fig. 5(b)]. The formation
of a flat surface-fractured zone was attributed to fine grains
and more amount of strain fields in the matrix. The formation
of voids was attributed to the pullout of precipitates. However,
deformed cum coalesced dimples, river pattern fractured
zone, and voids were observed in the furnace-cooled sample
[Fig. 5(c)]. The deformed cum coalesced dimples and the
river pattern-fractured zone was associated with more in
deformation and work hardening occurred in the sample.
The deformed cum coalesced dimples were attributed to
coarse grains and fewer strain fields in the matrix.[26]
Figure 5. SEM fracture surface of Incoloy 800 H under different conditions: (a) as-received (AR); (b) air-cooled (AC); and (c) furnace-cooled (FC).
The cutting force components (Fx, Fy, and Fz) attained
during machining of as-received forged condition and differ-
ent heat-treated conditions are listed in Table 1. The variation
of cutting force (Fz) on the cutting speed and feed rate with
different heat-treated conditions is shown in Fig. 6. It was
found that air-cooled sample exhibited more cutting force
values when compared to other two different conditions in
all the tested cutting parameters. This result was expected to
the presence of fine grains in the matrix and higher value of
mechanical strength. In contrast, the furnace-cooled sample
exhibited less cutting force values when compared to other
two different conditions in all the tested cutting parameters.
This result was attributed to the presence of coarse grains,
more amounts of precipitates, and lower value of mechanical
strength. However, the as-received forged conditioned sample
had shown more value of cutting force when compared to
furnace-cooled sample. This was attributed to ferrite stringers
and somewhat lesser grain size in the matrix compared to
furnace-cooled sample. The range of cutting force components
values (Fz) was 106.99–224.85 N for AR condition, 148.99–
312.01 N for AC condition, and 101.38–201.29 N for FC
condition. Figure 6(a) shows the variation of cutting force with
the function of feed rate at V ¼ 35 m/min for instance,
whereas Fig. 6(b) shows the variation of cutting force with
the function of cutting speed at f ¼ 0.02 mm/rev. These two
graphs [Fig. 6(a) and (b)] were drawn on the same y-axis scale
in which the average cutting force of 200N was mentioned.
Figure 6(a) demonstrates clearly that air-cooled sample
influenced more followed by the as-received sample. However,
the furnace-cooled sample had exhibited lower cutting forces
and it was not influenced much by the function of feed rate.
This was expected to the presence of coarse grains and preci-
pitates in the matrix. Further, the cutting force had started to
increase with the function of feed rate under all the conditions.
The increasing trend of cutting force with the feed rate was
attributed to more friction occurred amidst the tool and the

Figure 6. Variation of cutting force (Fz) of Incoloy 800 H under different conditions: (a) at cutting speed, V ¼ 35 m/min; (b) at feed rate, f ¼ 0.02 mm/rev.
workpiece in addition to the effect of grain size, ferrite
stringers, and amount of precipitates. Similar behavior
was seen for the other values of cutting speed (45 and
55 m/min). Figure 6(b) explains legibly that the cutting speed
was not influenced much by the cutting force when compared
to the feed rate. However, the cutting force had started to
decrease with the cutting speed under all the conditions. The
reduction of cutting force was attributed to thermal softening
that occurs because of high temperature at the machining
zone. However, the furnace-cooled sample had exhibited the
very low value of cutting force when compared to other two
conditions. This was expected to the presence of coarse grains,
lower mechanical strength value, and precipitates in the matrix
in addition to thermal softening. Similar behavior was noticed
for the other values of feed rate (0.04 and 0.06 mm/rev). The
results exhibited by feed force (Fx) and thrust force (Fy) with
the variation of cutting parameters were similar in trend pro-
duced by cutting force (Fz). As discussed, the heat treatment
process given to the Incoloy 800H had formed the precipitates,
produced different grain sizes, and varied the material’s mech-
anical strength; eventually, it had improved its machinability
when compared to the as-received forged condition. These
results were well correlated with the other researchers found
in elsewhere.[28,29]
Surface quality plays a significant role in fatigue life and
performance of the machined parts. Table 1 illustrates the
surface roughness of the machined samples under various
heat-treated conditions. Figure 6 shows the 3D surface profile
obtained from the high-resolution white light interferometer
for the machined sample of AR [Fig. 7(a)], AC [Fig. 7(b)],
and FC [Fig. 7(c)] at the higher cutting speed (55 m/min)
and the lower feed rate (0.02 mm/rev) as an example. In
general, the plowing effect of cutting tool insert would greatly
influence the surface finish of the machined components. This
plowing effect would cause small grooves on the machined
surfaces and hence it has to be minimized. It was found
from 3D surface profiles (Fig. 7) that the air-cooled samples
[Fig. 7(b)] had exhibited more small groves when compared
to other two samples [Fig. 7(a) and (c)]. These results were
explained that severe plowing effect had occurred in the air-
cooled sample due to more strain fields and higher value of
mechanical strength. Further, the as-received forged con-
ditioned sample also had shown some severe grooves.
MATERIALS AND MANUFACTURING PROCESSES 1599
This was attributed to more mechanical strength and some-
what smaller grain size when compared to furnace-cooled
sample. However, the furnace-cooled sample had shown neg-
ligible grooves only which indicated that a good surface finish
was obtained in the furnace-cooled sample. This result was
expected to the presence of coarse grains, precipitates, and
lower value of mechanical strength. These results were
explained that the coarse grains, amount of precipitates, and
low value of mechanical strength in the Incoloy 800H had
promoted immediate shearing action which resulted in a good
surface finish. The range of surface roughness obtained from
the experiments under different heat-treated conditions is
0.82–1.66 µm for AR, 1.30–2.08 µm for AC, and 0.30–1.03 µm
for FC. Figure 8 shows the variation of surface roughness with
the function of the feed rate at V ¼ 35 m/min and the cutting
speed at f ¼ 0.02 mm/rev as an example. Figure 8(a) clearly
demonstrates that the surface roughness value started to
increase with the function of feed rate. This was attributed
to increasing of successive tool path gaps which led to produc-
ing more peak and valley height in the turned profile. The
higher value of peak and valley height indicated more in
surface roughness value which meant poor in surface finish.
Both air-cooled and as-received conditioned samples were
influenced more by the function of feed rate when compared
Figure 7. 3D surface profile of the machined samples with different
conditions at V ¼ 55 m/min and f ¼ 0.02 mm/rev: (a) as-received; (b) air cooled;
and (c) furnace cooled.
1600 A. PALANISAMY ET AL.
Figure 8. Variation of surface roughness (Ra) of Incoloy 800 H under different conditions: (a) at cutting speed, V ¼ 35 m/min; (b) at feed rate, f ¼ 0.02 mm/rev.
to furnace-cooled sample. Similar behavior was noticed for the
other cutting speeds (45 and 55 m/min). However, decreasing
of surface roughness with the function of cutting speed under
different heat-treated conditions is shown in Fig. 8(b). Here
also, the furnace-cooled sample had exhibited a very low value
of surface roughness when compared to the other two different
conditions. Similar behavior was noticed for the other feed
rates (0.04 and 0.06 mm/rev). In general, the temperature
would start to increase as the cutting speed increases which
leads to producing thermal softening between the tool and
work material.[9,30] Due to this thermal softening effect at
higher cutting speed, the observed surface roughness value
was low in all the samples. Based on Fig. 8, it can be
concluded that a good surface finish was obtained in the fur-
nace-cooled sample due to the presence of coarse grains and
precipitates, and its lower mechanical strength value, whereas
poor in the surface finish was obtained in the air-cooled
sample due to the high mechanical strength value.
Conclusion
In this analysis, the interaction between microstructure,
material property, and machinability on dry turning as a result
of the effect of heat treatment in an Incoloy 800H with
uncoated carbide tool inserts were elaborately investigated
and reported. The following concluding points were drawn,
relating to the selected parameters and the experimental
results.
. The microstructural analysis in terms of grain size, grain
size distribution, and twins were explained clearly. These
results explained that fine grains were observed in the air-
cooled sample, whereas coarse grains were observed in
the furnace-cooled sample
. The formation of chromium carbides as precipitates was
confirmed through SEM analysis on the furnace-cooled
sample. The size of the grain, the amount of precipitates,
and strain fields had defined the strength of the sample in
which air-cooled sample had shown more mechanical
strength due to its finer grain size and more amount of
strain fields.
. The observed lower value of mechanical strength in the
furnace-cooled sample was attributed to the presence of
coarse grains and precipitates in the matrix.
. Incoloy 800H under air-cooled condition had induced
higher cutting force (312.01 N) when compared with under
furnace-cooled condition (201.21 N) during the dry turning
operation.
. The observed surface roughness was better at
V ¼ 55 m/min and f ¼ 0.02 mm/rev than other combina-
tions of selected parameters. The better surface finish was
obtained during the machining of the sample under
furnace-cooled condition.
. Incoloy 800H superalloy under furnace-cooled (FC) con-
dition had provided better machinability compared with
AC and AR samples at V ¼ 55 m/min and f ¼ 0.02 mm/rev.
ORCID
S. Sivasankaran http://orcid.org/0000-0002-7456-375X
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