Cite this article Metals Research Article Keywords: manufacturing/material

Tasbasi M, Ay M and Etyemez A (2020) Paper 2000194 processing/surface

Quality in turning of Inconel X-750 superalloy. Received 17/07/2020; Accepted 09/10/2020
Emerging Materials Research 9(4): 1154–1162, Published online 16/11/2020
https://doi.org/10.1680/jemmr.20.00194
ICE Publishing: All rights reserved

Emerging Materials Research

Quality in turning of Inconel X-750 superalloy

Muhammet Tasbasi
Graduate student, Faculty of Technology, Marmara University, Istanbul,
Turkey (Orcid:0000-0001-5166-7874)
Mustafa Ay
Professor, Department of Mechanical Engineering, Faculty of Technology,
Marmara University, Istanbul, Turkey (Orcid:0000-0001-2345-6789)
Ayhan Etyemez
General Manager, Engineering Department, Nikken Turkey, Istanbul,
Turkey (Orcid:0000-0001-8188-2743) (corresponding author:
ayhan@nikken.com.tr)

This study has been conducted to analyse the effects of turning the Inconel X-750 superalloy, which is a member of
a nickel-based superalloy family that is frequently preferred in the aerospace and nuclear energy industries in
particular, under minimum quantity lubrication (MQL), cryogenic liquid nitrogen (LN2) and carbon dioxide gas (CO2)
cooling/lubrication conditions, with different cutting speeds (Vc = 65, 95, 125 and 155 m/min) and constant feed rate
(f = 0.1 mm/revolution) and cutting depth (a = 0.5 mm) parameters, on the processability of Inconel X-750, hence on
the surface integrity. In this context, the results obtained from the tests have been comparatively examined through
surface roughness, tool wear and chip formation. Comparison results show that the cryogenic carbon dioxide
method has generally provided the best surface roughness and tool wear values. The MQL method has provided the
best chip formation.

Notation Imran et al. concentrated on surface integrity and wear

a cutting depth
f feed rate
L processing length
Ra surface roughness
Vc cutting speed
1. Introduction
Superalloys are special alloys that have oxidation and corrosion
resistance in extremely high temperatures. Nickel (Ni)-based alloy
groups are the most used superalloys. These superalloys are used in
various industries such as aircraft, spacecraft, medical devices,
steam turbines, marine applications, automotive applications and so
on. Nickel-based superalloys can preserve their mechanical,
physical, and structural properties in extremely high temperatures.
These features enable the material to be readily used within a
temperature ranging from −217 to 700°C. Features such as high
oxidation resistance, corrosion resistance, high yield strength, high
tensile strength and low creep ratio are the most prominent reasons
why nickel alloys are widely used. At the same time, these features
put these alloys into the less workable materials category. In order
for all parameters that affect the processability of nickel alloys to be
properly understood and included in production processes in the
best way, experimental studies should be conducted, taking into
account as many variables as possible in the processability of nickel
alloys, and the results should be perceptibly reported in detail.1
Many research studies have been conducted regarding the
processability of nickel alloys. In the literature, the matter of
increasing the processability of nickel alloys have been generally
approached through optimisation of machining conditions, and
cooling and lubrication methods with different characteristics
have been used.2–7 According to the studies conducted, the
cooling/lubrication methods used for increasing the processability
of nickel alloys have different advantages and disadvantages.8
mechanisms related to the mechanics of microstructures of
Inconel 718 nickel-based superalloy under dry and cooling/
lubrication supported cutting conditions. Their study includes the
projection of guidance on the selection of cutting conditions for
acceptable surface integrity.9 Tebaldo et al. studied processing the
Ti–48Al–2Cr–2Nb alloy under minimum quantity lubrication
(MQL), dry and standard cutting fluid conditions and tackled the
results in terms of tool life, surface quality, oil consumption, and
environmental impact. According to the results of their study, they
indicated that the use of different emulsion rates was more
advantageous compared to MQL and dry cutting applications, and
flow rate together with the type of cutting fluid were the variables
that significantly affected the cutting performance.10 Kumar et al.
studied the effect of turning Inconel 718 using carbide tools under
different cutting conditions on the surface quality. They
emphasised the superior performance of processing under MQL
conditions.11 Ibrahim et al. conducted experimental studies to
research the effect of cutting parameters and machining on the
surface integrity under three different cutting conditions. They
concluded that a serious deformation occurred in the
microstructure as a result of the tests, causing microstructure
changes of a few micron thickness under the surface, and the
surface integrity characteristics of MQL can be enhanced.12
Cordes et al. conducted a study to comparatively test the cooler
transfer methods, designed for effective processing using carbon
dioxide gas (CO2) as a cryogenic cooler, with other cooling
methods. They concluded that the cryogenic cooler combination
of the cooler transfer methods provided environmental and
economic benefits together with high cutting parameters, high
material removal rates and less tool wear.13 In a study discussing
the processing of Inconel 718 under traditional and cryogenic
cooling conditions in terms of surface integrity, approaching from
a different perspective, Iturbe et al. concluded that traditional
cooling was the best option in terms of both processability and

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surface integrity.14 Shokrani et al. researched cryogenic milling of
the Inconel 718 alloy using titanium aluminium nitride (TiAlN)-
coated carbide tools. They concluded that, compared to the
dry processing, cryogenic cooling had significant potential
in improving the surface roughness of processed pieces and in
minimum tool wear, without causing a significant increase in
power consumption.15 In his study, Kaynak conducted a
comparative research on the tool wear characteristics, cutting
forces, chip morphology and surface roughness features of
processing the Inconel 718 alloy under dry, cryogenic and MQL
conditions. He stated that, compared to other methods, cryogenic
processing yielded quite good results in terms of high-temperature
wear and surface quality.16 Balan et al. conducted an experimental
study on the effects of processing Inconel 751 under dry, MQL
and cryogenic cooler-supported MQL system (Cryo-MQL)
conditions on cutting forces, temperature, surface roughness and
chip morphology. They concluded that compared to MQL and dry
processing, processing with liquid nitrogen (LN2) and MQL
combination significantly reduced the cutting forces and surface
roughness; also, the same combination reduced the specific
cutting energy by more than 50% compared to traditional dry
processing, and therefore, the Cryo-MQL combination was
remarkably effective.17 Shokrani et al. tested the MQL, cryogenic
cooling, and hybrid Cryo-MQL cooling/lubrication techniques on
the milling process of aged Inconel 718. According to the results
of their study, they discovered that the hybrid Cryo-MQL cooling/
lubrication system increased the processability remarkably,
virtually doubled the tool life and increased the surface roughness
by more than 15%.18 Adopting an innovative approach to the
processing of Inconel 718, Pereira et al. studied cooling with
Cryo-MQL lubrication, as an internal coolant, to support the
development of more environment-friendly processing systems.
They made comparisons with other cooling/lubrication methods to
prove the benefits of new methods. The results of their research
have shown that the performance of internal Cryo-MQL was more
effective compared to that of other individual eco-friendly
methods such as external Cryo-MQL or MQL.19
In many studies in the literature, the cryogenic cooling method,
which is a more effective cooling method than traditional
cooling/lubrication methods, has been proposed as a solution to
high-temperature-based problems during superalloy and
machining operations. This method is generally performed by
applying liquid nitrogen directly or indirectly on the cutting area,
workpiece, cutting tool or different combinations of those, and the
general opinion is that this is a positive method in terms of human
health and the environment. In recent years, many studies have
been carried out on the comparative analysis of different cooling/
lubrication methods such as the cryogenic method, methods using
traditional cutting fluids, dry processing methods, MQL, and
combinations of those. With certain studies, it has been observed
that the importance of the Cryo-MQL cooling/lubrication method,
where cryogenic cooler and MQL methods, a combined cooling/
lubrication method, have been used together, has increased
compared to other methods.
Emerging Materials Research 2020.9:1154-1162.
Quality in turning of Inconel X-750
superalloy
Tasbasi, Ay and Etyemez
This study examined the effects of turning the Inconel X-750
superalloy on machinability, and thus surface integrity, under dry,
MQL, cryogenic liquid nitrogen and carbon dioxide gas cooling/
lubrication conditions, with different cutting speeds (Vc = 65, 95,
125 and 155 m/min), a constant feed rate (f = 0.1 mm/revolution)
and cutting depth (a = 0.5 mm) parameters. In this context, the
results of the experiments were comparatively studied in terms of
surface roughness, tool wear and chip formation.
2. Materials and methods
2.1 Materials
Inconel X-750, a computer numerical control (CNC) turning lathe,
special cutting inserts for processing the superalloy, devices to
measure and analyse forces, a device to measure and analyse
surface roughness, a metallurgy microscope, an MQL device, MQL
lubrication fluid, high-purity liquified cryogenic liquid nitrogen and
high-purity carbon dioxide gas were used as test equipment and
materials in the experiments of this study (Figure 1).
2.2 Test parameters
In order to analyse different cooling/lubrication methods under
cutting forces in different cutting speeds (Vc), the change of forms
on the surface after processing, the state of surface roughness, the
processing length (L = 50 mm) and the feed rate (f = 0.1 mm/
revolution) have been kept constant; on the other hand, cutting
speeds (Vc = 65, 95, 125 and 155 m/min) and cooling/lubrication
conditions (dry, MQL, cryogenic carbon dioxide gas and
cryogenic liquid nitrogen) have been considered as variables. As
shown in Table 1, four different cutting speed parameters were
used for each cooling/lubrication condition, and the tests made
using the cutting speed that corresponded to each cooling/
lubrication method were denoted with the initials of the cooling/
lubrication methods and the numbers according to the cutting
speed. The test parameters given in Table 1 are presented in detail
in Table 2.
A JohnFord T35 industrial-type CNC turning lathe, a TP60 tank
of brand Aeroliquid with 0.5 bar pressurised cryogenic liquid
nitrogen, cryogenic carbon dioxide gas and LubriOil MQL oil
were used in the tests. Besides, a Kistler 5080A amplifier, a
Kistler 5697 data processing system and a Kistler 9121 three-
component (X, Y, Z) piezoelectric quartz dynamometer system
were used for measuring the cutting forces formed during cutting.
‘Kistler DynoWare’ software was used to transfer the forces to the
computer environment and to monitor them. The Mitutoyo
Surftest SJ-410 model was used for surface roughness
measurements.
In the experiments, eight samples with 23 HRC hardness,
19.30 mm diameter and 150 mm length were used (Figure 2). The
chemical content of the Inconel X-750 nickel-based superalloy
provided by the supplier is presented in Table 3, its mechanical
properties are presented in Table 4 and its physical properties are
presented in Table 5.
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Tasbasi, Ay and Etyemez

CO2

MQL

LN2

(a) (b)

(c) (d) (e)

Figure 1. Test equipment and preparation of the test set-up:20 (a) JohnFord TC35 CNC turning lathe; (b) Kistler 9121 dynamometer;
(c) Kistler 5080 A-type load amplifier; (d) Kistler 5697 model data processing system; (e) Mitutoyo Perthometer SJ-410

In the experiments, eight pieces of ‘Sumitomo’ AC510U-grade
physical vapor deposition (PVD) (titanium aluminium nitride and
aluminium chromium nitride (AlCrN) multilayer) carbide inserts
in CCMT09T304N-SU form (Figure 3) were used with a left-
hand turning tool holder that was made of steel of SCLCL type
and 2020K06 geometry with medium-level toughness (Figure 4).
calculated after the cutting tests. Surface roughness values were
obtained by calculating the arithmetic average, and these test
averages are shown in Table 6. The average surface roughness
values of the test obtained by using different cooling/lubrication
methods together with different cutting speeds are presented
comparatively and graphically in Figure 5.

3. Test results and evaluation

Table 2. Detailed description of test parameters
The feed rate and cutting depth (a = 0.5 mm) parameters have
been kept constant, whereas cooling/lubrication methods and Test Cutting Feed rate, Cutting
Cooling/
cutting speeds have been considered as variables. The results of number speed, Vc: f: mm/ depth,
lubrication
(test code) m/min revolution a: mm
cutting tests are discussed in terms of surface roughness after the
process, tool wear states and the states of produced chips under 1 (D1) Dry processing 65 0.1 0.5
separate titles. 2 (D2) Dry processing 95 0.1 0.5
3 (D3) Dry processing 125 0.1 0.5
4 (D4) Dry processing 155 0.1 0.5
3.1 Evaluation of surface roughness results 5 (M1) MQL 65 0.1 0.5
Regional average values of surface roughness measurement 6 (M2) MQL 95 0.1 0.5
results on pre-marked regions on the processed pieces were 7 (M3) MQL 125 0.1 0.5
8 (M3) MQL 155 0.1 0.5
9 (C1) Carbon 65 0.1 0.5
dioxide gas
Table 1. Test methods and parameters 10 (C2) Carbon 95 0.1 0.5
dioxide gas
Processing
Name/value 11 (C3) Carbon 125 0.1 0.5
method/parameter
dioxide gas
Cooling/lubrication Dry, MQL, carbon dioxide gas and 12 (C4) Carbon 155 0.1 0.5
method liquid nitrogen dioxide gas
Cutting speed, Vc: m/min 65,95,125 and 155 13 (L1) Liquid nitrogen 65 0.1 0.5
Feed rate, f: 0.1 14 (L2) Liquid nitrogen 95 0.1 0.5
mm/revolution 15 (L3) Liquid nitrogen 125 0.1 0.5
Cutting depth, a: mm 0.5 16 (L4) Liquid nitrogen 155 0.1 0.5

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Tasbasi, Ay and Etyemez

Table 5. Physical properties of the Inconel X-750 nickel-based

superalloy material20
Specific heat Thermal
Temperature Density
capacity conductivity
°F °C °F °C °F °C
Figure 2. Inconel X-750 nickel-based superalloy test piece20
°F °C lb/ g/ Btu/ J (Btu in.)/ W/
in.3 cm3 (lb °F) (kg °C) (h ft2 °F) (m K)

Table 3. Chemical content of the Inconel X-750 nickel-based 70 21.1 0.299 8.28 0.103 431.2 83 11.97
superalloy material20
Content Content: %
r
Tantalum (Ta) 0.010
d
Carbon (C) 0.040

odi
Manganese (Mn) 0.040
Silicon (Si) 0.080
Boron (B) 0.004
Phosphorus (P) 0.005 80º l s
Sulfur (S) 0.001
Chromium (Cr) 15.630
Iron (Fe) 7.700 Figure 3. ‘Sumitomo’ AC510U-grade cutting insert in
Nickel (Ni) 72.050 CCMT09T304N-SU form20
Copper (Cu) 0.010
Cobalt (Co) 0.020
Aluminium (Al) 0.760
Titanium (Ti) 2.580
h1 h
Niobium (Nb) 0.850

Examining Figure 5 and taking into consideration surface

roughness values based on test averages, it was observed that the
lowest surface roughness values were provided by the turning
operation using the cryogenic carbon dioxide gas method at
95 m/min cutting speed and that the highest surface roughness
values were provided by the tests made under the cryogenic
carbon dioxide gas and liquid nitrogen conditions at 65 m/min
cutting speed and the tests under dry processing conditions at
155 m/min cutting speed. According to the test results, the idea
that cryogenic methods in nickel-based superalloys give positive
results in reducing the surface roughness, similarly to other
materials with lower processability index, is relatively
consistent.16,21–27 On the other hand, test results have shown that
the idea that traditional methods provided better surface roughness
than did MQL and cryogenic methods was questionable.
However, test results supported the idea of better critical analysis
and design of test parameters to clarify further the superiority
state of cooling/lubrication methods against each other.10,28–31
f b
95º L
Figure 4. SCLCL2020K06-type turning tool holder20
3.2 Evaluation of tool wear results
After the tests, the status of the tool wear that formed on the
cutting inserts used with the cutting speeds corresponding to each
cooling/lubrication method was examined under the microscope.
The top and side views of the cutting insert are shown in the
figures.
To examine the effects of the conducted processing tests on the
formed tool wear, the tool wear statuses are indicated in Figure 6
for dry processing (125 m/min), Figure 7 for MQL processing

Table 4. Mechanical properties of the Inconel X-750 nickel-based superalloy material19

Temperature Short-term tensile strength tests
Yield strength with 0.2% offset Maximum tensile strength
°F °C Elongation (50.8 mm): % Reduction of area: %
ksi MPa ksi MPa
70 21.1 92 634 161 1110 22 30
1000 538.0 83 572 140 965 20 30
1200 649.0 82 565 120 827 10 21
1400 760.0 68 469 80 552 10 22
1500 816.0 45 310 47 324 20 32

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Table 6. Average test values of surface roughness measurements

Surface roughness, Ra: µm

1.2
Surface 1.0
Cutting
Test Feed rate, roughness 0.8
Cooling/ speed,
number f: mm/ test
lubrication Vc: m/ 0.6
(test code) revolution average,
min 0.4
Ra: µm
1 (D1) Dry processing 65 0.1 0.989 0.2
2 (D2) Dry processing 95 0.1 0.902 0
3 (D3) Dry processing 125 0.1 0.876 65 95 125 155
4 (D4) Dry processing 155 0.1 1.039 Cutting speed, Vc: m/min
5 (M1) MQL 65 0.1 0.890
6 (M2) MQL 95 0.1 0.830 Dry MQL CO2 LN2
7 (M3) MQL 125 0.1 0.882
8 (M4) MQL 155 0.1 0.901 Figure 5. Comparison of the tests made under different cooling/
9 (C1) Carbon dioxide 65 0.1 1.057 lubrication conditions and in different cutting speeds in terms of
gas average surface roughness test values
10 (C2) Carbon dioxide 95 0.1 0.767
gas
11 (C3) Carbon dioxide 125 0.1 0.883
gas crack line formed. On the other hand, notch formation was
12 (C4) Carbon dioxide 155 0.1 0.881 observed on two different points in the C3 test. Other than some
gas exceptions, the tool damage in the cryogenic liquid nitrogen and
13 (L1) Liquid nitrogen 65 0.1 1.057 carbon dioxide gas tests was directly proportional to the cutting
14 (L2) Liquid nitrogen 95 0.1 0.893
15 (L3) Liquid nitrogen 125 0.1 0.882
speed in general, while the biggest damages under MQL and dry
16 (L4) Liquid nitrogen 155 0.1 0.934 processing conditions were observed in the tests with the highest
cutting speed. The test results do not support the idea that
cryogenic methods reduce the tool wear.15,32–36 Moreover, the test
(125 m/min), Figure 8 for carbon dioxide gas processing (125 m/min) results support the idea that the cutting operations made under dry
and Figure 9 for liquid nitrogen processing (125 m/min), with the processing conditions are less efficient compared to other methods
mentioned cutting speeds. in terms of tool wear.29,34,35,37

Examining the images showing the tool wear status in the tests
under different cooling/lubrication conditions with different
cutting speeds, the biggest wear in terms of notch damage
appeared in L1 at 65 m/min cutting speed, followed by C1 at
65 m/min, M4 at 155 m/min and D4 at 155 m/min (Figure 10).
Besides the notch formation in the D4 test, a significantly long
3.3 Evaluation of chip formation
The formations of chips obtained from the tests made under different
cooling/lubrication conditions at different cutting speeds were first
compared internally for each cooling/lubrication method. Then, the
tests made in all cooling/lubrication methods with different cutting
speeds were examined in terms of chip formations.

0.055 mm
0.020 mm

0.045 mm

0.4 mm 0.4 mm

(a) (b)

Figure 6. D3, 125 m/min, tool wear status in the dry processing test: (a) top view and (b) side view

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0.095 mm

0.070 mm

0.085 mm

0.085 mm

0.4 mm 0.4 mm
(a) (b)

Figure 7. M3, 125 m/min, tool wear status in the MQL processing test: (a) top view and (b) side view

0.100 mm

0.065 mm

0.090 mm

0.090 mm 0.120 mm

0.4 mm 0.4 mm
(a) (b)

Figure 8. C3, 125 m/min, tool wear status in the carbon dioxide gas processing test: (a) top view and (b) side view

Of the processing tests made with chip formations, only those
with 125 m/min cutting speed are presented in Figure 11; in
Figure 11, chip formation in (a) dry (125 m/min), (b) MQL
(125 m/min), (c) carbon dioxide gas (125 m/min) and (d) liquid
processing with the mentioned cutting speeds are shown.
Examining the images that show chip formation in the tests made
under different cooling/lubrication conditions at different cutting
speeds, the chip formation with the best flow was observed in the
tests under MQL conditions. Regular chip formation in small
quantities was observed in the tests made under cryogenic liquid
nitrogen conditions; however, both regular and irregular chip
formations were observed in the same test. In the chips obtained
from the tests under cryogenic carbon dioxide gas conditions,
chip flow improved and became regular with increasing cutting
speed; on the other hand, chips formed under dry processing
conditions were more regular at lower cutting speeds, while
they were becoming more irregular at high cutting speeds. The
test results supported the idea that the MQL method was
significantly effective in terms of chip formation in the processing
of nickel alloys.10,29,37 Also, the idea that the cryogenic methods
needed further development in terms of chip formation was
supported.
4. Conclusion
The test results obtained from the turning tests made for the
Inconel X-750 (UNS N07750/W. Nr. 2.4669) nickel-based
superalloy under dry, MQL, cryogenic carbon dioxide gas and
cryogenic liquid nitrogen conditions and using different cutting
speeds can be summarised below.

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Tasbasi, Ay and Etyemez

0.140 mm

0.085 mm

0.070 mm

0.075 mm

0.4 mm 0.4 mm

(a) (b)

Figure 9. L3, 125 m/min, tool wear status in the liquid nitrogen processing test: (a) top view and (b) side view

0.545 mm

0.205 mm

0.075 mm

0.050 mm

0.4 mm 0.4 mm

(a) (b)

Figure 10. D4, 155 m/min, tool wear status in the dry processing test: (a) top view and (b) side view

■ The turning test has provided the best surface roughness average
(Ra) values; the cutting speed of 95 m/min under cryogenic
carbon dioxide gas conditions, and all methods exhibited values
close to each other at the cutting speed of 125 m/min. At low
cutting speeds, the carbon dioxide gas and liquid nitrogen
methods showed the worse surface roughness values.
■ Out of all the tests, the test made under dry processing
conditions at the cutting speed of 155 m/min had the most
tool wear status observed, and no crack formation was
observed except for this test. In addition to the above, the
biggest tool wear was observed in the cryogenic carbon
dioxide gas and cryogenic liquid nitrogen tests at the cutting
speed of 65 m/min, and the tests with the third and fourth
biggest tool wear were the dry and MQL tests at the cutting
speed of 155 m/min, respectively.
■ In terms of chip formation, the best chip flow was observed in
the tests made under MQL conditions, and the unstable chip
flow was observed under cryogenic liquid nitrogen conditions.
Also, it was observed that more regular chip flow was
obtained with increasing cutting speed in the chips formed in
the cryogenic carbon dioxide tests.
Acknowledgments
Experiments were carried out by using the experimental
equipment taken within the scope of the FEN-C-YLP-141118-
0596 project supported by BAPKO of Marmara University.

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(a)
(c)
Figure 11. Chip formation under different cooling/lubrication conditions at 125 m/min cutting speed: (a) dry (125 m/min); (b) MQL
(125 m/min); (c) carbon dioxide gas (125 m/min); (d) liquid nitrogen (125 m/min)
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