This presentation discusses advancements in the machining of additively manufactured and wrought refractory and high-temperature metals and alloys, which are integral to applications in defense, energy, aerospace, electronics, medical, and nuclear industries. These materials are employed in demanding applications—ranging from hypersonic components to higher temperature turbine applications—owing to their superior temperature resistance and durability.
Despite these advantages, widespread utilization is constrained by factors such as high raw material costs, slow manufacturing throughput, significant tool wear, and elevated defect rates. Conventional machining and forming methods, as well as secondary processing for additively manufactured components, remain expensive and technically challenging.
Recent developments in synthetic fluorinated metalworking fluids (MWFs) have demonstrated notable improvements in machining efficiency and part quality for refractory and high-temperature metals. The DoE Nuclear National Security Agency and multiple commercial users have validated increases in throughput, extended tool life, and enhanced surface finish when compared to conventional coolants for materials such as tungsten, tantalum, molybdenum, niobium, titanium, C103, TZM, and high-temperature nickel alloys. These fluids are non-hazardous, chemically inert, nonflammable, and compatible with existing equipment and application techniques, thus not requiring additional capital investment.
The presentation will feature new machining data generated in collaboration with Lawrence Livermore National Laboratory, Georgia Institute of Technology, EWI, and Kratos SRE, highlighting comparative studies of efficiency, tool life, and surface quality achieved with synthetic fluorinated MWFs versus alternative fluids. Additional results from Georgia Institute of Technology will detail chip morphology, cutting forces, and chip and workpiece surface analyses, providing insight into the mechano-chemical mechanisms underlying the observed improvements in machining performance.
Learning Objectives:
Understand the unique challenges involved in post machining additively manufactured refractory and high-temperature metals and alloys, particularly for demanding applications in defense, energy, aerospace, electronics, medical, and nuclear industries.
Explore the recent advances in metalworking fluids, including their impact on machining efficiency, part quality, tool life, and surface finish for refractory and high-temperature metals.
Analyze comparative data from leading research institutions and industry partners on the performance of synthetic fluorinated metalworking fluids versus conventional coolants.
