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Sustainable machining of heat resistant superalloys using hybrid nanofluid based minimum quantity lubrication.

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Názov: Sustainable machining of heat resistant superalloys using hybrid nanofluid based minimum quantity lubrication.
Autori: Chohan, Jasgurpreet Singh, Samantaray, Sikata, Bupesh Raja, V. K., Patil, Nagaraj, Kaladhar, M., Mann, Vikasdeep Singh, Abate, Lema, Ghodhbani, Refka
Zdroj: Scientific Reports; 9/30/2025, Vol. 15 Issue 1, p1-17, 17p
Predmety: NANOFLUIDS, HEAT resistant alloys, MECHANICAL wear, NICKEL alloys, AEROSPACE engineering, LUBRICATION systems, SUSTAINABILITY, LUBRICANT additives
Abstrakt: Improving the machinability of nickel-based superalloys remains a significant challenge in modern manufacturing, particularly for aerospace and high-performance engineering applications. Excessive friction and elevated temperatures during machining often result in rapid tool wear and reduced efficiency. This study investigates the potential of eco-friendly hybrid nanofluids—engineered by combining nanoparticles with complementary thermal and lubricating characteristics—as a sustainable solution to enhance machining performance. Specifically, the performance of three hybrid nanofluid combinations—hexagonal boron nitride/graphite (hBN/Gr), hBN/molybdenum disulfide (MoS₂), and Gr/MoS₂—was evaluated during the milling of Inconel 601 under varied cutting speeds (30–60 m/min) and feed rates (0.05–0.15 mm/rev). Key machining responses such as cutting force, surface roughness, tool wear, temperature, and tool life were analyzed. Among the tested combinations, the hBN/Gr nanofluid demonstrated superior performance, achieving reductions in cutting force (4.17%), surface roughness (21.05%), cutting temperature (8.57%), and tool wear (19.25%), along with an 11.17% improvement in tool life compared to Gr/MoS₂. These enhancements are attributed to the fluid's optimal viscosity and exceptional tribological behavior at the tool–chip interface. The study offers a novel, environmentally responsible approach to machining Inconel 601, emphasizing the promising role of hybrid nanofluids—particularly hBN/Gr—as next-generation lubricants in sustainable manufacturing. [ABSTRACT FROM AUTHOR]
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Abstrakt:Improving the machinability of nickel-based superalloys remains a significant challenge in modern manufacturing, particularly for aerospace and high-performance engineering applications. Excessive friction and elevated temperatures during machining often result in rapid tool wear and reduced efficiency. This study investigates the potential of eco-friendly hybrid nanofluids—engineered by combining nanoparticles with complementary thermal and lubricating characteristics—as a sustainable solution to enhance machining performance. Specifically, the performance of three hybrid nanofluid combinations—hexagonal boron nitride/graphite (hBN/Gr), hBN/molybdenum disulfide (MoS₂), and Gr/MoS₂—was evaluated during the milling of Inconel 601 under varied cutting speeds (30–60 m/min) and feed rates (0.05–0.15 mm/rev). Key machining responses such as cutting force, surface roughness, tool wear, temperature, and tool life were analyzed. Among the tested combinations, the hBN/Gr nanofluid demonstrated superior performance, achieving reductions in cutting force (4.17%), surface roughness (21.05%), cutting temperature (8.57%), and tool wear (19.25%), along with an 11.17% improvement in tool life compared to Gr/MoS₂. These enhancements are attributed to the fluid's optimal viscosity and exceptional tribological behavior at the tool–chip interface. The study offers a novel, environmentally responsible approach to machining Inconel 601, emphasizing the promising role of hybrid nanofluids—particularly hBN/Gr—as next-generation lubricants in sustainable manufacturing. [ABSTRACT FROM AUTHOR]
ISSN:20452322
DOI:10.1038/s41598-025-14204-8