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<p>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&#xa0;m/min) and feed rates (0.05–0.15&#xa0;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.</p>

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

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年9月30日

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  • Jasgurpreet Singh Chohan,
  • Sikata Samantaray,
  • V. K. Bupesh Raja,
  • Nagaraj Patil,
  • M. Kaladhar,
  • Vikasdeep Singh Mann,
  • Lema Abate,
  • Refka Ghodhbani

摘要

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.