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<p>The recycling of GH4738 superalloy machining chips can significantly reduce the manufacturing costs of hot-end components. However, surface contaminants such as cutting fluid residues and dense oxide layers prevent the chips from meeting revert material quality standards. Existing cleaning methods often suffer from low efficiency, secondary pollution, or inadequate removal of highly resistant oxides. To address this, an effective stepwise alkaline-acid cleaning process was developed. The alkaline cleaning employed an optimized synergistic system of a nonionic and an anionic surfactant. Under mild conditions of 40°C and 600 W ultrasound, the complementary actions of hydrophilic ether shells and sulfonic acid groups ensured high emulsion stability, enabling efficient removal of cutting fluid and reducing the total oxygen content by 87.4%. Subsequent acid pickling with 1&#xa0;mol/L HCl and 3 vol.% H<sub>2</sub>O<sub>2</sub> reduced O, N, and S impurities to levels comparable to the bulk alloy within 30&#xa0;min. Cl<sup>-</sup> created weak points in the oxide layer, while H<sub>2</sub>O<sub>2</sub> suppressed its self-repair, collectively accelerating oxide dissolution through chemical and electrochemical actions. This work provides a viable pretreatment strategy for superalloy machining scrap recycling, with implications for removing other challenging surface contaminants.</p>

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A Stepwise Cleaning Process for High-Quality Superalloy Machining Scrap Recycling: Efficient Removal of Cutting Fluid Residues and Oxides

  • 期刊论文

  • 发表日期：

    2026年6月23日

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  • Yuzhe Liu,
  • Chunlin He,
  • Zeyuan Zhao,
  • Hongyu Zhang,
  • Yalei Han,
  • Shuai Liu,
  • Yizhou Zhou,
  • Yuan Sun

摘要

The recycling of GH4738 superalloy machining chips can significantly reduce the manufacturing costs of hot-end components. However, surface contaminants such as cutting fluid residues and dense oxide layers prevent the chips from meeting revert material quality standards. Existing cleaning methods often suffer from low efficiency, secondary pollution, or inadequate removal of highly resistant oxides. To address this, an effective stepwise alkaline-acid cleaning process was developed. The alkaline cleaning employed an optimized synergistic system of a nonionic and an anionic surfactant. Under mild conditions of 40°C and 600 W ultrasound, the complementary actions of hydrophilic ether shells and sulfonic acid groups ensured high emulsion stability, enabling efficient removal of cutting fluid and reducing the total oxygen content by 87.4%. Subsequent acid pickling with 1 mol/L HCl and 3 vol.% H2O2 reduced O, N, and S impurities to levels comparable to the bulk alloy within 30 min. Cl- created weak points in the oxide layer, while H2O2 suppressed its self-repair, collectively accelerating oxide dissolution through chemical and electrochemical actions. This work provides a viable pretreatment strategy for superalloy machining scrap recycling, with implications for removing other challenging surface contaminants.