Development of non-destructive evaluation methods for the determination of machining deformation of high-performance Ni-based superalloys

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The project aims to develop a non-destructive tool for the evaluation of deformation during machining operations and will aid the transition to Industry 4.0. Over the past few years efforts have concentrated on the development of methodologies that can be used to non-destructively evaluate machining deformation. A method developed at the AMRC that has exhibited considerable promise is the use of X-ray diffraction that has been shown to qualitatively determine machining deformation. This project aims to build upon the existing body of work at the AMRC to develop this methodology further to allow the quantitative evaluation of deformation on Ni-based superalloy components with the ultimate aim of developing a process that can be integrated onto machining rigs providing real-time data of deformation accumulation. The project will hence result in significant cost savings to be realised as tool-life will be determined in real-time, whilst also providing an accurate measure of deformation further aiding in the data-driven transformation of manufacturing processes. In order to achieve the aims outlined, the project will concentrate on developing the methodology on Ni-based superalloys that offer a unique combination of challenges both in machining and diffraction that will enable a robust methodology to be determined and extended to lab-based systems. The project objectives are: -Methodology development and advanced understanding through high resolution experiments using synchrotron radiation on machined samples with different levels of deformation. -Extension of lessons learned from synchrotron diffraction to lab-based ex-situ methodologies including the determination of the usable limits of theory in lab-based systems and the establishment of data analysis protocols and algorithms. -Trials of in situ integration to machining rigs.