Effects of Machined Surface Integrity on High-Temperature Low-Cycle Fatigue Life and Process Parameters Optimization of Turning Superalloy Inconel 718

Machined surface integrity characteristics, including surface stresses, physical-mechanical properties and metallographic structures, play important roles in the fatigue performance of machined components. This work aimed at investigating the effects of machined surface integrity on high-temperature low-cycle fatigue life. The process parameters were optimized to obtain required surface integrity and fatigue life of the turning superalloy Inconel 718. The relationships between low-cycle fatigue life and machined surface integrity characterization parameters were established based on the low-cycle fatigue tests at a high temperature (650 °C). The sensitivities of turning process parameters to high-temperature low-cycle fatigue life were analyzed, and the optimization parameters were proposed with the goal of antifatigue manufacturing. Experimental results indicated that the impact order of the characterization parameters of machined surface integrity on the high-temperature low-cycle fatigue life were the degree of work hardening R(HV), the residual stress in the cutting speed direction S(22), the fatigue stress concentration factor K(f), the degree of grain refinement R(D) and the residual stress in the feed direction S(33). In the range of turning parameters of the experiments in this research, the cutting speeds could be 80~110 m/min, and the feed rate could be 0.10~0.12 mm/rev to achieve a longer high-temperature low-cycle fatigue life. The results can be used for guiding the fatigue-resistant manufacturing research of aeroengine superalloy turbine disks.