Surface damages and tool wear mode in end milling of hastelloy-C276 under dry and wet conditions Oberflächenschäden und Werkzeugverschleiß beim Trocken- und Nassfräsen von Hastelloy-C276 M. Al-Falahi 1 , F. Fadaeifard 2 , M. D. A. Al-Falahi 3 , B. T. H. T. Bin Baharudin 4 , T. S. Hong 4 Hastelloy-C276 is a nickel based superalloy that is widely used in chemical, petro- chemical, environmental and nuclear industries due to its outstanding performance in a wide range of corrosive mediums. The superior properties of nickel based superalloys impair their machinability which increases the difficulty in obtaining a good surface finish. Because most of the components’ failures are initiated from sur- face defects, several researchers have been concerned about surface integrity in machining aerospace superalloys particularly Inconel-718. Due to the lack of studies done on machining corrosion-resistant superalloys, this study aims to investigate surface damages and tool wear modes in milling Hastelloy-C276 under dry and wet conditions. The absence of cooling and lubricating actions in dry machining resulted in the formation of craters, severe plastic deformation, voids, debris re-deposition and materials drag. The breakage of the nucleated carbide phases resulted in the formation of nucleated cavities on the machined surface in both wet and dry machin- ing. Adhesive tool wear was less in dry machining due to the formation of oxide layers on tool faces which suppressed the formation of built-up edges due to the weak adhesion properties of oxide compounds which resulted in less surface rough- ness at v c = 50 m/min. On the other hand, the higher temperature and friction in dry machining resulted in severer tool coating delamination. Keywords: Wet and dry machining / corrosion resistant superalloys / surface damages / adhesion / coating delamination Hastelloy-C276 ist eine hochkorrosionsbeständige Nickel-Basislegierung, die in der Chemietechnik, Petrochemietechnik, Umwelttechnik und Nuklearindustrie ange- wendet wird. Wegen ihrer hohen Warmfestigkeit zählen Nickel-Basislegierungen zu den schwer zerspanbaren Werkstoffen, weshalb eine hohe Oberflächengüte schwer zu erzielen ist. Da die Güte der Werkstückoberflächen einen großen Einfluss auf die funktionalen Merkmale der Produkte wie z. B. Zuverlässigkeit, Sicherheitsstandard und Lebensdauer hat, werden die Oberflächenschäden, die durch die Bearbeitung Corresponding author: Muath Al-Falahi, Ryan Wilks Pty Ltd, Unit 23/28 Vore Street, Silverwater NSW 2128, Australia, E-Mail: muatha@ryanwilks.com.au 1 Ryan Wilks Pty Ltd, Unit 23/28 Vore Street, Silver- water NSW 2128, Australia 2 Materials synthesis and characterization lab, Institute of advance technology, University Putra Malaysia, 43400 Serdang, Malaysia 3 National Centre for Ports & Shipping, Australian Mar- itime College, University of Tasmania, Maritime Way, Newnham Tasmania 7250, Australia 4 Department of mechanical and manufacturing engi- neering, Faculty of engineering, University Putra Ma- laysia, 43400 Serdang, Malaysia Mat.-wiss. u. Werkstofftech. 2016,1–11 DOI 10.1002/mawe.201600534 © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.wiley-vch.de/home/muw 1