Papers by Author: Pawel Rokicki

Abstract: Nickel-base superalloys like Alloy 625 are widely used in power generation applications due to their unique properties especially at elevated temperatures. During the related component manufacturing for gas turbines up to 50% of the material has to be removed by metal cutting operations like milling, turning or drilling. As a result of high strength and toughness the machinability of Alloy 625 is generally poor and only low cutting speeds can be used. High-speed cutting of Alloy 625 on the other hand gets more important in industry to reduce manufacturing times and thus production costs. The cutting speed represents one of the most important factors that have influences on the tool life. The aim of this study is the analyses of wear mechanisms occurring during machining of Alloy 625. Orthogonal cutting experiments have been performed and different process parameters have been varied in a wide range. New and worn tools have been investigated by stereo microscopy, optical microscopy and scanning electron microscopy. Energy-dispersive X-ray analyses were used for the investigation of chemical compositions of the tool's surface as well as the nature of reaction products formed during the cutting process. Wear mechanisms observed in the machining experiments included abrasion, fracture and tribochemical effects. Specific wear features appeared depending on the mechanical and thermal conditions generated in the wear zones.

Abstract: Nickel-base superalloys like Alloy 625 are widely used in power generation applications and in the oil and gas industry due to their unique properties especially at elevated temperatures. The chip formation process of Alloy 625 is not yet well understood. Therefore, the cutting process of this alloy has been studied in detail by means of orthogonal cutting experiments at conventional cutting speeds and in the high-speed cutting regime. Alloy 625 shows a cutting parameter dependent change in the chip formation process from continuous to segmented chips. Silver has been added to Alloy 625 to improve the machinability. During machining of these modified alloys short breaking chips develop so that cutting processes are eased and can be automated.

Abstract: An alloy containing Al – 3wt.% Cr – 3wt.% Fe – 0.8wt. % Ce, was prepared by melt spinning. Structure of obtained ribbons was observed by light, scanning and transmission electron microscopy. It was found out that the structure is very fine. Microhardness of cross sectioned ribbons was also measured. Defects in structure were determined by positron annihilation spectroscopy. The thermal stability of the alloy was observed by comparing rapidly solidified ribbons and ribbons annealed at 400°C and at 500°C for 100 h