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<p>Duplex stainless steel (DSS) alloys have been extensively applied in the petroleum, chemical, and energy sectors owing to their exceptional mechanical properties and high resistance to oxidation and corrosion. However, these advantageous characteristics come at the cost of diminished machinability. In addition, milling these challenging materials tends to produce grooved profiles on machined surfaces. Therefore, this study investigated the surface integrity during dry end milling of four DSS alloys: 2101, 2304, 2205, and 2507. To explore the effects of the cutting parameters, such as the cutting speed (<i>v</i><sub><i>c</i></sub>), feed per tooth (<i>f</i><sub><i>z</i></sub>), and axial depth of cut (<i>a</i><sub><i>p</i></sub>), a randomized Box–Behnken experimental design was performed. The results show that surface roughness exhibited significant variability, with the response variables (<i>R</i><sub><i>a</i></sub> and <i>R</i><sub><i>z</i></sub> values) being concurrently optimized. Each DSS variant demonstrated specific optimal levels for the cutting parameters. Accelerated corrosion tests executed according to the ASTM G48 standard indicated varying pit sizes, notably larger for 2101 and 2304. The mass loss was correlated with the smallest medium maximum height of the profile (<i>R</i><sub><i>z</i></sub>). In cases where <i>R</i><sub><i>z</i></sub> values ranged from 1.6 to 3.9&#xa0;µm, 20 to 30&#xa0;pits/mm<sup>2</sup> were observed within scratches and grooves left by the end mill tool. Energy-dispersive spectroscopy analysis shows elevated levels of sulfur, indicating possible inclusions and a high chromium content at the center of the pits.</p>

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Surface integrity analysis of machined duplex stainless steel alloys by dry end milling

  • 期刊论文

  • 发表日期：

    2025年5月27日

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  • Mauricio R. Policena,
  • Émerson S. Passari,
  • André J. Souza

摘要

Duplex stainless steel (DSS) alloys have been extensively applied in the petroleum, chemical, and energy sectors owing to their exceptional mechanical properties and high resistance to oxidation and corrosion. However, these advantageous characteristics come at the cost of diminished machinability. In addition, milling these challenging materials tends to produce grooved profiles on machined surfaces. Therefore, this study investigated the surface integrity during dry end milling of four DSS alloys: 2101, 2304, 2205, and 2507. To explore the effects of the cutting parameters, such as the cutting speed (vc), feed per tooth (fz), and axial depth of cut (ap), a randomized Box–Behnken experimental design was performed. The results show that surface roughness exhibited significant variability, with the response variables (Ra and Rz values) being concurrently optimized. Each DSS variant demonstrated specific optimal levels for the cutting parameters. Accelerated corrosion tests executed according to the ASTM G48 standard indicated varying pit sizes, notably larger for 2101 and 2304. The mass loss was correlated with the smallest medium maximum height of the profile (Rz). In cases where Rz values ranged from 1.6 to 3.9 µm, 20 to 30 pits/mm2 were observed within scratches and grooves left by the end mill tool. Energy-dispersive spectroscopy analysis shows elevated levels of sulfur, indicating possible inclusions and a high chromium content at the center of the pits.