Optimising abrasive water jet cutting parameters for direct metal laser sintered Inconel 718: a study of cutting efficiency and surface quality

Additive manufacturing techniques are being employed to enhance the characteristics of Inconel 718 for gas turbine applications. This material is extensively utilised due to its exceptional high-temperature strength and corrosion resistance. The study involved the application of solution treatment and thermal ageing (HT) on additively manufactured (AM) Inconel 718. Subsequently, the process of abrasive water jet cutting (AWJC) is executed, utilising diverse input variables such as water pressure, traverse speed, abrasive mass flow rate, and Stand Off Distance (SOD). The study involved experimenting with the effects of each factor at three distinct levels, followed by the application of Analysis of Variance (ANOVA) to ascertain the factor that exerted the most significant influence on the surface roughness of both untreated and treated samples. The findings of the data analysis indicate that the traverse speed exerted a more significant influence on the surface roughness of the base sample than the abrasive mass flow rate. Conversely, it is evident that the mass flow rate of the abrasive had a more significant influence on the surface roughness of the specimens subjected to heat treatment. The study emphasised the importance of careful selection of appropriate abrasive mass flow rates and traverse speeds to achieve effective processing of Inconel 718 through the use of AWJs. Additive manufacturing techniques enhance Inconel 718 for gas turbine applications.Inconel 718 valued for high-temperature strength and corrosion resistance.Study applies solution treatment and thermal ageing to AM Inconel 718.Abrasive water jet cutting (AWJC) parameters include water pressure, traverse speed, abrasive mass flow rate, and Stand Off Distance (SOD).Factors tested at three levels; Analysis of Variance (ANOVA) identifies influential factors on surface roughness.Traverse speed more influential on untreated samples' surface roughness; abrasive mass flow rate more impactful post-heat treatment.Study underscores the critical role of selecting optimal AWJC parameters for effective Inconel 718 processing.