A State-of-the-Art Review on Cutting Tool Materials and Coatings in Enhancing the Tool Performance in Machining the Superior Nickel-Based Superalloys

Nickel-based superalloys have gained widespread use in various industries like aerospace, power generation, chemical processing, and marine engineering due to their exceptional mechanical properties. However, machining these superalloys poses significant challenges due to their hardness. To address these issues and improve machining performance, selecting suitable cutting tool materials and coatings is crucial. This state-of-the-art review aims to provide an in-depth understanding of the latest research on cutting tool materials and coatings in enhancing the tool performance in machining the superior nickel-based superalloys. It begins by examining the applications and current challenges associated with machining these alloys. Different types of cutting tool materials, including cemented carbides, ceramic-based tools, and super-hard materials like polycrystalline cubic boron nitride, are analyzed, with a particular focus on tool geometry and failure. The advantages, limitations, and specific applications of each tool material are highlighted. Additionally, the role of coatings in enhancing cutting tool performance is explored. Various coating types, including titanium nitride (TiN), titanium carbonitride (TiCN), and aluminum oxide (Al₂O₃), are evaluated based on their effectiveness in machining nickel-based superalloys. The review also covers aspects such as tool wear, cutting forces, the surface roughness of machined parts, heat generation, and temperature measurement techniques employed by researchers to assess cutting tool performance. It underscores the importance of tailoring the selection of cutting tool materials and coatings to specific machining conditions for optimal results. The review concludes by summarizing key findings and suggesting potential areas for future research.