Effect of different cooling/lubrication regimes on machinability properties in the miling of Hastelloy X super alloy

The serious developments in the space and aviation sector in recent years have also contributed to the development of material technology. In parallel with the development of material technology, superalloy materials with superior properties have been developed. In addition to the superior properties of these materials called superalloys, there may be difficulties in their shaping. In order to overcome these difficulties, researchers have accelerated their work to develop sustainable methods. In this study, the Hastelloy X superalloy material used in the space and aviation field was milled under sustainable cooling/lubrication conditions. Milling experiments were carried out in two stages. In the first stage, it was aimed to investigate the effects of particle sizes of nanofluids on machining performance. For this purpose, dry, minimum quantity lubrication (MQL), 4 nm sized Al2O3, 48 nm sized Al2O3 and 136 nm sized Al2O3 nanofluid cooling/lubrication conditions were preferred. In the second stage, it was aimed to investigate the effects of dry, MQL, Al2O3 added nanofluid, vortex, CO2, MQL+vortex, nanofluid+vortex, CO2+MQL, CO2+nanofluid cooling/lubrication conditions on the machining performance. In order to investigate the effects of cooling/lubrication conditions, the cutting speed, feed rate and cutting depth parameters were taken as 50 m/min, 0.10 mm/rev and 0.5 mm, respectively. Surface roughness Ra, cutting temperature and power consumption values were determined as performance criteria. According to the results obtained from the first stage experiments, 4 nm sized Al2O3 nanofluid exhibited superior performance compared to other conditions. 4 nm sized Al2O3 nanofluid condition showed a decrease of 37.43%, 36.02% and 8.33% in surface roughness, cutting temperature and power consumption results, respectively, compared to the dry condition. According to the results obtained from the second stage experiments, better performance was obtained in Al2O3+CO2 hybrid condition compared to other conditions. In Al2O3+CO2 hybrid condition, surface roughness, cutting temperature and power consumption results decreased by 50.98%, 51.84% and 9.375%, respectively, compared to the dry condition.