Screw Machining of Inconel Parts

Screw Machining of Inconel Parts

2024-10-14 by Cherry

Introduction

With the continuous development of industrial technology, 

die casting machines, as one of the indispensable equipment

in modern manufacturing, are widely used in industries 

such as automobiles, aerospace, and consumer electronics. 

As an important part of the die-casting machine, the material

and process selection of screws and other fasteners directly

affect the performance and life of the equipment. As a 

high-performance nickel-based alloy, Inconel has gradually 

become the preferred material for die-casting machine parts 

screw processing due to its excellent high-temperature durability,

corrosion resistance and mechanical strength. 

This article will focus on the application of Screw Machining 

of Inconel Parts in the field of die-casting machines, and

discuss its importance and prospects in detail from the 

aspects of material selection, process, advantages and disadvantages, 

application fields, development trends, etc.

1. Material selection for Screw Machining of 

Inconel Parts

1. Introduction to Inconel

Inconel is a superalloy mainly based on nickel and chromium,

with excellent oxidation resistance and corrosion resistance,

especially in high-temperature environments. Several major 

alloy types of Inconel (such as Inconel 625 and Inconel 718) 

can maintain extremely high mechanical strength under high-temperature

conditions, so they are often used in harsh industrial 

environments.

In the processing of screws for die-casting machine parts, the

high-temperature stability and corrosion resistance of the material

are key considerations. During the die-casting process, the mold,

heating system, and hydraulic device are often in a state of 

high temperature and high pressure. Traditional steel materials

are prone to failure under such extreme conditions, while 

Inconel can maintain stable physical properties for a long time.

2. High-temperature performance of materials

When the die-casting machine is working, the mold temperature

usually reaches 400-600℃, and even higher in some cases. At

this time, screws, as important parts for connection and fixing,

need to withstand extremely high thermal and mechanical stresses.

For the working environment involving high-temperature molten metal

in the die-casting machine, Inconel's heat resistance makes it 

very suitable for key components such as screws.

Inconel has an extremely wide operating temperature range and can 

remain stable in a high-temperature environment of 600°C to 

1000°C. Due to its excellent high-temperature creep resistance,

it can work for a long time in such extreme environments without

thermal fatigue and screw loosening. In addition, the low expansion

coefficient of Inconel helps reduce the stress concentration caused

by thermal expansion, thereby avoiding screw breakage.

3. Corrosion resistance of materials

During the die-casting process, the mold and screws may come

into contact with high-temperature molten metal, which places

strict requirements on the corrosion resistance of the material.

The chromium and nickel content in Inconel alloy enables it to

maintain excellent tolerance in corrosive environments such as 

oxidation and sulfidation, and shows extremely high resistance in 

chemically corrosive environments, and can resist corrosion from

various acids, alkalis, and oxidants.

The die-casting machine is in contact with liquid metal and other

corrosive substances for a long time, so corrosion resistance is 

an important criterion for the selection of screw materials. This 

is crucial to extend the service life of the screws and the entire

die-casting machine.

4. High strength and fatigue resistance

Inconel has extremely high mechanical strength and will not

show fatigue cracks under repeated high-pressure environments, 

which is crucial for die-casting machine screws that are frequently

subjected to stress. Traditional Steel may deform or break under

high temperatures and long-term stress, while Inconel can ensure

the stable operation of the equipment in the long term.

These characteristics make Inconel the preferred material for 

manufacturing high-performance die-casting machine screws. 

It can not only meet the working requirements of high-temperature

and high pressure, but also ensure the stability and reliability

of the equipment in extreme environments.

Screw Machining of Inconel Parts

Although Inconel materials are excellent, their high strength 

and high hardness make the processing process full of challenges,

especially for screw parts with extremely high processing precision.

The following are the main process steps for Screw Machining of 

Inconel Parts:

1. Material preparation and selection:

First, it is necessary to select and prepare Inconel materials.

Commonly used Inconel alloys include Inconel 625, Inconel 718, 

etc. They each have different mechanical properties and chemical

compositions and are suitable for different working conditions.

2. Challenges of precision machining

Due to its high hardness and toughness, Inconel is difficult 

to process, especially in the manufacturing process of precision 

parts such as screws, the processing equipment, and process 

requirements

are extremely demanding. Normally, due to the high hardness

and toughness of Inconel materials, Screw Machining of Inconel

Parts screws require the use of special high-strength carbide 

tools, such as tungsten carbide or ceramic tools. The cutting

speed must be low to avoid overheating of the material and 

hardening. At the same time, high-efficiency coolant must be

used to reduce the temperature and reduce tool wear.

Combined with advanced CNC (computer numerical control) 

technology to ensure processing accuracy and surface quality.

Parameters such as cutting speed, feed rate, and cutting 

depth must be strictly controlled to avoid overheating of the

material surface or tool wear.

2.1 Turning

Turning is a common process in the Screw Machining of Inconel 

Parts. During the turning process, we need to select appropriate

tools and cutting parameters to ensure the quality and accuracy 

of the processed surface. At the same time, it is also necessary

to pay attention to controlling the cutting temperature to 

avoid material deformation or tool wear due to excessive 

temperature.

2.2 Milling

Milling is mainly used to process the threaded part of Inconel

parts screws. During the milling process, we need to select

appropriate milling cutters and milling processes to ensure

the dimensional accuracy and surface quality of the thread.

At the same time, it is also necessary to pay attention to

controlling the milling speed and feed rate to avoid burrs or

cracks on the thread surface due to excessive processing speed.

2.3 Drilling

Drilling is an essential process in the screw processing 

of Inconel parts. During the drilling process, we need to

select the appropriate drill bit and drilling process to 

ensure the dimensional accuracy and surface quality of the

drilled hole. At the same time, it is also necessary to 

pay attention to controlling the drilling speed and feed 

rate to avoid the drill bit breaking or cracks on the drilling

surface due to excessive drilling speed.

2.4 Thread processing: The most critical part of the screw is

thread processing, which requires highly precise turning 

and grinding processes. CNC machine tools are widely used 

in this process to ensure the accuracy and consistency of 

the thread.

3. Cooling and lubrication technology

The high-temperature hardness of Inconel materials poses a

challenge to the durability of cutting tools. Therefore, 

high-efficiency coolants must be used for cooling and lubrication

during processing to reduce tool wear and heat generated on 

the processing surface. Coolants can not only improve processing

efficiency but also extend tool life, thereby reducing 

production costs.

4. Heat treatment and surface treatment technology

After the screws are processed, heat treatment and surface 

treatment is usually required to improve their durability.

4.1 Heat treatment: To improve the hardness and wear

resistance of the screws, Screw Machining of Inconel Parts usually 

needs to undergo heat treatment. Heat treatment can further improve 

it's high-temperature resistance and fatigue resistance, which

is especially important for screws frequently used in die-casting

machines.

4.2 Surface treatment: After processing, Screw Machining of 

Inconel Parts usually need to be surface treated. Common surface

treatment methods include nickel plating, oxidation treatment,

etc. To enhance its corrosion resistance and wear resistance,

to ensure that it still maintains good performance under 

long-term working conditions of the die-casting machine.

5. Quality inspection and control

Screw Machining of Inconel Parts'quality inspection and control

are crucial links. We need to use advanced testing equipment and

testing methods to strictly inspect and control each link in the

processing process to ensure that the processed parts' screws meet

the design requirements and quality standards. At the same time,

it is also necessary to establish a complete quality management 

system, strengthen the management and supervision of the 

processing process, and improve the quality stability, and reliability 

of the products.

Advantages and Disadvantages of Screw Machining 

of Inconel Parts

Advantages

1. Excellent high-temperature resistance: Inconel has excellent

strength performance at high temperatures, which is far better

than ordinary steel, which enables it to operate stably for 

a long time in high-temperature working environments such as 

die-casting machines. Inconel can maintain its mechanical 

strength and stability at temperatures up to 1000°C, which 

is very suitable for use in the high-temperature operating 

environment of die-casting machines.

2. High strength and fatigue resistance: Inconel alloy will 

not have fatigue cracks under repeated high pressure, ensuring

the long-term stable operation of the die-casting machine 

under high load.

3. Excellent corrosion resistance: Its corrosion resistance is

not only reflected in chemical corrosion resistance under 

conventional environments, but also includes oxidation resistance

under high temperature and high pressure, so that Screw Machining 

of Inconel Parts can remain durable under harsh conditions. Inconel 

alloy's tolerance to oxidation, corrosion, acid, and alkali

environments give it a significant advantage in the high

temperature and high-pressure environment of die-casting 

machines, which can greatly extend the service life of parts

such as screws.

4. Creep and oxidation resistance: Die-casting machine screws

will deform due to material creep at high temperatures, while

Screw Machining of Inconel Parts can prevent this phenomenon 

from happening at extreme temperatures.

5. Excellent mechanical properties

Even under extreme conditions, Screw Machining of Inconel Parts

can still maintain high mechanical strength and toughness, 

which is particularly important for fasteners such as screws,

and can effectively avoid failure due to fatigue and creep.

Disadvantages

1. Difficult processing

The high hardness and toughness of Inconel make it extremely

demanding on tools during processing. It is easy to cause tool

wear and long processing time during cutting and processing,

and the cost of processing equipment increases. At the same

time, the technical requirements for processing personnel 

are more stringent, which increases production costs.

2. High material cost

As a high-end alloy material, Inconel's raw materials are 

expensive and the cost is relatively high. Especially in 

mass production applications, the high cost of materials 

may become a constraint.

3. High cooling requirements: For Screw Machining of Inconel

Parts, an efficient cooling system must be used, otherwise,

it will cause the material to harden, thereby increasing 

the difficulty of processing.

Application of Screw Machining of Inconel Parts

in die-casting machine field

1. Fixing and connecting die-casting molds

In die-casting machines, a large number of screws are required

for the installation and fixing of molds, and these screws

must be able to maintain stability and reliability in high-temperature

and high-pressure working environments. The high-temperature 

stability and corrosion resistance of Screw Machining of Inconel Parts

give them significant advantages in such applications. They 

tightly connect the clamping mechanism, injection mechanism,

hydraulic system, electrical control system, and other parts to

ensure that the various components of the die-casting machine will

not loosen or separate during high-speed operation. Ensure the precise 

installation and fixing of the mold to avoid mold loosening 

during production.

2. Seals for high-pressure hydraulic systems

1. The hydraulic system is an important part of the die-casting

machine and Screw Machining of Inconel Parts are particularly widely used in

hydraulic systems. Since hydraulic systems often work under 

high pressure and high temperature, Inconel materials can ensure

that the screws will not fail due to fatigue or corrosion 

during long-term use, and can withstand high pressure, maintain

long-term sealing, and avoid hydraulic oil leakage, thereby 

ensuring the stability and reliability of the system. In some

key parts of the die-casting machine, such as the injection 

cylinder and the mold closing cylinder, the Screw Machining of 

Inconel Parts can effectively prevent the leakage of hydraulic

oil and the entry of external impurities, ensuring the 

normal operation and service life of the die-casting machine.

3. Application in the heating system

During the die-casting process, the metal needs to melt 

and flow at high temperatures and the heating system of 

the die-casting machine needs to handle high-temperature 

molten metal. Therefore, the screws that fix the heating 

elements need to have extremely high heat resistance. 

Inconel screws can not only withstand high temperatures, 

but also resist the chemical corrosion of molten metal, 

thereby greatly improving the service life of the heating 

system.

4. Casting system parts: Inconel's anti-oxidation ability

at high temperatures makes it play an irreplaceable role

in the casting system of the die-casting machine, and 

can effectively resist the erosion of molten metal.

5. Transmission force and torque: In the working process of 

the Lijin die-casting machine, the Screw Machining of Inconel Parts

also need to transmit force and torque. They transmit 

the power of the motor to each working part, so that the 

die-casting machine can complete the actions of mold closing,

injection, and mold opening.

Application case of Screw Machining of Inconel Parts 

in the die-casting machine

To better illustrate the application effect of Inconel parts 

screws in the die-casting machine, we will introduce a 

practical application case below.

A certain automobile parts manufacturer uses LJ die-casting

machine to produce aluminum alloy automobile wheels. 

During the production process, due to the harsh working

environment of the die-casting machine, high temperature,

and strong corrosiveness, ordinary parts screws are prone

to deformation, corrosion, and other problems, resulting 

in high equipment failure rate and low production efficiency.

Later, the company adopted Inconel parts screws to 

effectively solve these problems. 

The high temperature and corrosion resistance of Inconel

parts screws enable it to maintain good performance in

harsh working environments, greatly improving the reliability 

and stability of the die-casting machine. At the same time,

the excellent mechanical strength and toughness of Inconel 

parts screws also enable it to withstand greater force and

torque, improving the working efficiency and production

quality of the die-casting machine.

Development trend of Screw Machining of Inconel Parts

1. Automation and intelligent processing

With the advancement of Industry 4.0, the development of 

intelligent manufacturing and automation technology in the 

field of die-casting machines will promote further optimization

of Inconel parts processing technology, and Inconel parts 

screw processing is gradually developing in the direction of 

intelligence. Through advanced CNC machining centers and machine 

learning algorithms, through digital and intelligent means, 

complex Inconel parts can be processed more efficiently and 

production efficiency can be improved. In the future, real-time

monitoring and adjustment of the screw processing process can

be achieved to further improve processing efficiency and product

quality.

2. Development of new materials

Although Inconel is one of the most representative alloys

in current high-temperature applications, with the continuous 

advancement of materials science, new alloy materials with

better performance than Inconel may be developed in the 

future. For example, by adding other rare metal elements to

Inconel, or by improving the internal structure of the material

through nanotechnology, its durability and processability

can be further improved.

With the enhancement of global environmental awareness, green

manufacturing has become a new direction for the development 

of die-casting machines. The high durability and high recyclability

of Inconel materials make it meet the requirements of green

manufacturing and can effectively reduce resource waste.

3. Material innovation

In the future, with the development of materials science, 

new Inconel alloy materials may be developed to further 

improve their mechanical properties, corrosion resistance 

and processability, thereby broadening their application range 

in die-casting machines.

Prospects of Screw Machining of Inconel Parts

in the field of die-casting machines

With the continuous development and progress of industrial 

technology, the application fields of die-casting machines 

are becoming more and more extensive, and the performance

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