Secure machining for tough surfaces

Sandvik Coromant has launched two new turning grades specifically designed for the machining of heat resistant super alloy (HRSA) materials. The S205 turning grade for finishing and semi-finishing and the Ceramic CC6165 grade for roughing to semi-finishing applications are designed for machining difficult surfaces in HRSAs.

HRSAs are typically used for aircraft parts that face extreme performance demands. Their high strength at elevated temperatures means the materials can retain their hardness when facing intense heat. The demand for lower emissions, higher fuel efficiency and power density in the transport and energy makes HRSA materials particularly valuable in these applications.

Because HRSA materials are metallurgically composed to have high strength at temperatures up to 1,000 degrees Celsius, the stresses generated when machining them are high.The unique capability of these nickel, iron and cobalt-based super alloys to perform close to the melting point of their basic metal gives them generally poor machinability.

Sandvik Coromant's new turning grades are optimized with these machining challenges in mind. Developed for last stage machining applications in aerospace engine components, the S205 is a chemical vapour deposition (CVD) grade that offers increased productivity through higher cutting speeds in semi finishing and finishing applications.

Coated with second generation Inveio® coating for high wear resistance and long tool life, post treatment technology strengthens the S205 insert by modifying its mechanical properties. The Inveio® technology forms tightly packed uni-directional crystals around the insert to create a strong protective barrier, while delivering maximum thermal protection to improve crater wear and flank wear resistance.

Ideal for use with aged nickel-based materials and pre-machined surfaces, for machining components such as aircraft engine turbine discs, rings and shafts, the S205 boasts 30 to 50% higher cutting speeds than competing HRSA turning grades without compromising tool life.

The qualities of the CC6165 turning grade also offer superior resistance. Made from SiAION ceramic, a specialist class of high-temperature refractory materials with high strength at high temperature, the CC6165 is optimized for roughing and intermediate stage machining HRSAs as well as for profile and general turning applications.

Similar to the S205, typical components machined with the CC6165 are turbine discs, casings rings and valves.

Following its predecessor, the CC6160 turning grade from Sandvik Coromant, the CC6165 has improved edge line toughness for secure machining of more demanding HRSA surfaces. It also allows for higher metal removal rates, helping to increase productivity and reduce the cost per component.

"While the CC6160 grade is the first choice for roughing to semi-finishing of pre-machined HRSAs in stable conditions, the new CC6165 is able to meet the demands of more difficult to machine surfaces," explained Rolf Olofsson, Product Manager at Sandvik Coromant.

"The CC6165 and the S205 have been developed to help machinists overcome the difficulties of HRSAs, so they can make the most out of the materials' unique benefits. In fact, analysis has demonstrated a 210% increase in tool life when using the S205 to machine an aged Inconel test bar, compared to results from a competing tool."

The introduction assortment of the S205 includes 36 items, with more to be added during spring 2021. The Ceramic CC6165 grade is also available in a range of assortments to meet the demands of varied industries and materials.

To learn more about Sandvik Coromant’s turning grades for HRSA materials visit here.