Analysis of surface integrity evolution of aero-engine nickel-based alloy Waspaloy in precision turning

The nickel-based superalloy Waspaloy is a critical material for aero-engine components. Its surface integrity is susceptible to degradation during machining processes, which consequently impairs the service performance of the machined components. This study systematically investigates the effects of cutting parameters on the surface integrity, including residual stress, surface morphology, and subsurface microstructure, using an integrated approach that combines finite element simulation and machining experiments. Results indicate that increasing cutting speed lowers the calibrated apparent fracture energy and intensifies adiabatic shear localization, leading to more uneven surface morphology and reduced surface residual stress. In contrast, raising the feed rate expands the plastic deformation zone and strengthens strain effects, promoting more stable chip separation. This results in a more regular surface texture and increased surface residual tensile stress. The simulation and experimental results show reasonable agreement. The results provide useful theoretical and experimental support for the machining of difficult-to-machine aerospace materials.