Inconel 718 is a Ni superalloy with superior mechanical properties, even at high temperatures. However, due to its high hardness and low thermal conductivity, it is considered a difficult-to-machine material. This material is widely used in applications that require good dimensional stability, making the milling process the most used in machining this alloy. The wear resulting from this process and the quality of the machined surface are still challenging factors when it comes to Inconel 718. TiAlN-based coating has been used on cutting tools with Yttrium as a doping element to improve the process performance. Based on this, this work evaluated the machined surface integrity and wear resistance of cutting tools coated using Physical Vapor Deposition (PVD) HiPIMS with TiAlYN in the end milling of Inconel 718, varying the process parameters such as cutting speed (v_c), feed per tooth (f_z), and cutting length (L_cut). It was verified that the L_cut is the parameter that exerts the most significant influence since, even at small distances, Inconel 718 already generates high tool wear (TW). Furthermore, the main wear mechanisms were abrasive and adhesive wear, with the development of a built-up edge (BUE) under a125 m/min feed rate (f) and a L_cut = 15 m. Chipping, cracking, and delamination of the coating were also observed, indicating a lack of adhesion between the coating and the substrate, suggesting the need for a good interlayer or the adjustment of the PVD parameters.

Injection moulds are crucial to produce plastic and lightweight metal components. One primary associated challenge is that these may suffer from different types of failures, such as wear and/or cracking, due to the extreme temperatures (T), thermal cycles, and pressures involved in the production process. According to the intended geometry and respective needs, mould manufacturing can be performed with conventional or non-conventional processes. This work focuses on three foremost alloys: AMPCO^® (CuBe alloy), INVAR-36^® (Fe-Ni alloys, Fe-Ni36), and heat-treated (HT) steels. An insight into the manufacturing processes’ limitations of these kinds of materials will be made, and solutions for more effective machining will be presented by reviewing other published works from the last decade. The main objective is to provide a concise and comprehensive review of the most recent investigations of these alloys’ manufacturing processes and present the machinability challenges from other authors, discovering the prospects for future work and contributing to the endeavours of the injection mould industry. This review highlighted the imperative for more extensive research and development in targeted domains.

The use of coatings on cutting tools offers several advantages from the point of view of wear resistance. A recent technique with great coating deposition potential is PVD HiPIMS. TiAlN-based coatings have good resistance to oxidation due to the oxide layer that is formed on their surface. However, by adding doping elements such as Vanadium, it is expected that the wear resistance will be improved, as well as its adhesion to the substrate surface. INCONEL^® 718 is a nickel superalloy with superior mechanical properties, which makes it a difficult-to-machine material. Milling, due to its flexibility, is the most suitable technique for machining this alloy. Based on this, in this work, the influence of milling parameters, such as cutting speed (V_c), feed per tooth (f_z), and cutting length (L_cut), on the surface integrity and wear resistance of TiAlVN-coated tools in the milling of INCONEL^® 718 was evaluated. The cutting length has a great influence on the process, with the main wear mechanisms being material adhesion, abrasion, and coating delamination. Furthermore, it was noted that delamination occurred due to low adhesion of the film to the substrate, as well as low resistance to crack propagation. It was also observed that using a higher cutting speed resulted in increased wear. Moreover, in general, by increasing the milling parameters, machined surface roughness also increased.

Many municipal facilities, such as pools and drinking water treatment facilities, are subject to ongoing maintenance due to the corrosion of their metallic materials caused by chlorine, leading to high costs and a possible risk to public health. A proper study of the employed product’s effect could lead to the use of better materials, which significantly increase the lifetime of metallic equipment more attacked by corrosion, through studies evaluating their cost-effectiveness. This paper was carried out with the objective of studying the degradation of some metallic materials (AISI 316L, AISI 321 and Duplex 14462) used in the referred facilities in order to select the one that possessed a better behavior. It was observed that the introduction of some more adequate materials can drastically reduce maintenance operations, with Duplex 14462 showing the best results, ideal for greater chlorine concentrations, followed by AISI 321, which may be employed for components in less contact with chlorine, since it is more easily affordable.

Machining INCONEL^® presents significant challenges in predicting its behaviour, and a comprehensive experimental assessment of its machinability is costly and unsustainable. Design of Experiments (DOE) can be conducted non-destructively through Finite Element Analysis (FEA). However, it is crucial to ascertain whether numerical and constitutive models can accurately predict INCONEL^® machining. Therefore, a comprehensive review of FEA machining strategies is presented to systematically summarise and analyse the advancements in INCONEL^® milling, turning, and drilling simulations through FEA from 2013 to 2023. Additionally, non-conventional manufacturing simulations are addressed. This review highlights the most recent modelling digital solutions, prospects, and limitations that researchers have proposed when tackling INCONEL^® FEA machining. The genesis of this paper is owed to articles and books from diverse sources. Conducting simulations of INCONEL^® machining through FEA can significantly enhance experimental analyses with the proper choice of damage and failure criteria. This approach not only enables a more precise calibration of parameters but also improves temperature (T) prediction during the machining process, accurate Tool Wear (TW) quantity and typology forecasts, and accurate surface quality assessment by evaluating Surface Roughness (SR) and the surface stress state. Additionally, it aids in making informed choices regarding the potential use of tool coatings.

Due to chlorine’s ability to kill bacteria and fungi through a chemical reaction, chlorine solutions are commonly used to clean and disinfect numerous public facilities, although these actions are also dependent to the equipment present in those facilities. Accordingly, the interest in studying its effect when in contact with different materials is obvious. This study was carried out through accelerated degradation tests and various analysis methods (optical microscope, scanning electron microscope, and tensile tests). The objective was to observe the wear presented by three polymeric materials, polyvinyl chloride (PVC), high-density polyethylene (HDPE), and polypropylene (PP), when exposed to chlorine’s action in swimming pools and drinking water treatment plants. The resulting effect depends on the chlorine content and the type of contact between the chemical agent and the material. The aim was to select the material less likely to be affected by chlorine through tests and analyses, allowing a longer component life. The use of certain more resistant polymeric materials can drastically reduce maintenance, reducing fundamental factors such as costs, the downtime of municipal facilities, and also the risk to public health. It was concluded that PVC has the most stable behaviour overall when in contact with chlorine solutions.