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2 Materials Science Poland

2 2025

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Investigation of burr formation and surface integrity in micro-milling of aluminum alloy LF21 slot

Wu Chao, Li Weimin, Tang Zhaoqing, Feng Shuai, Liang Jixiang, Li Jiahui

Materials Science Poland

2025

Vol. 43, No. 2

1--22

Due to the nature of LF21 aluminum alloy material, it is difficult to process and easily prone to plastic deformation; hence, micro-milling process is prone to produce larger burrs and rougher surface. Currently, there are fewer investigations on LF21 slot micro-milling. So, this article uses a combination of finite element simulation and experimentation to analyze the effects of different cutting parameters on the LF21 slot exit, top burr size, and the surface quality of the bottom of the slot. The results of the investigation show that the top burr and exit burr sizes as well as the surface roughness at the bottom of the groove show a monotonically decreasing trend as the spindle speed increases, especially on the up-milling side where the burr size is significantly smaller than that on the down-milling side. Variation in feed rate plays a pivotal role in burr size and groove bottom roughness. The smallest burr size, along with the best surface quality, is achieved when the feed per tooth is close to the tool edge radius. Furthermore, as the cutting depth increases, both the burr size and surface roughness also increase. This effect becomes particularly pronounced at larger cutting depths, where surface valleys are markedly higher and grooves become significantly deeper. The results of this investigation are instructive for practical micro-milling of aluminum alloy LF21, which is important for improving machining efficiency.

Effect of laser welding on the microstructure and properties of ultrathin Inconel 718 sheets

Wu Chao, Li Weimin, Tang Zhaoqing, Liang Jixiang, Li Jiahui

Materials Science Poland

2025

Vol. 43, No. 2

153--170

Inconel 718 is a high-strength, high-temperature alloy with a nickel matrix containing elements such as niobium (Nb) and molybdenum (Mo). It exhibits excellent corrosion resistance and high-temperature mechanical properties. It is widely used in the manufacture of critical sealing components. However, there is currently limited research on the welding of ultra-thin Inconel 718 sheets with a thickness of 0.25 mm. To address issues such as deformation and poor fusion during welding, this study proposes a combined approach of finite element simulation and experimental analysis to investigate the effects of pulsed laser welding parameters on the temperature field, weld morphology, and mechanical properties. The optimal process parameters obtained through orthogonal experiments were a laser power of 300 W, a welding speed of 60 mm/s, and a duty cycle of 55%. The results show that, with these parameters, the tensile strength of the weld was 856 MPa, approaching 80% of that of the base material, and the weld morphology was uniform and defect-free. The experimental and finite element simulation results were in good agreement. The microstructure at the weld was compact and uniform, with a reasonable distribution of Laves and δ phases, and no obvious defects were observed. This study provides valuable reference data for designing the actual laser welding process for Inconel 718 thin sheets.