Effects of cutting angle, edge preparation, and nano-structured coating on milling performance of a gamma titanium aluminide

Gamma titanium aluminides are intermetallic alloys. Recently, they have been evaluated as important contenders for structural applications in the automotive and aerospace sectors. This is due to their excellent high-temperature performances and their significantly lower density compared to Nickel-based superalloys. In this paper, an analysis of machinability of a gamma TiAl obtained via an electron beam melting (EBM) process is presented. The effects of tool geometry modifications, in terms of cutting tool angles and cutting edge preparation, were investigated. The reduction of radial rake angle and the drag finishing process for cutting edge preparation resulted in an increase of the tool life of the carbide end mills. Nanogradient tool coatings were also observed to affect tool wear during milling tests, and the results highlight that AlSiTiN coating performs better compared to CrAlSiN coating. A post-coating polishing treatment was also taken into account, and it allowed a further reduction of tool wear. The overall results indicate that the machinability of this difficult-to-cut material can be significantly improved by an adjustment of the cutting edge geometry, and by using an AlSiTiN coating system.