The influence of induction-assisted milling on the machining characteristics and surface integrity of γ-TiAl alloys

The gamma-TiAl alloys are characterized by low density, high specific strength, and excellent high-temperature performance, making it an ideal material for achieving lightweight and high-temperature durability in high-pressure compressors. However, due to its intrinsic embrittlement, conventional machining (CM) methods often lead to machining defects, making it difficult to meet industrial requirements. Induction-assisted machining (IAM) provides a new approach to improve the machinability of gamma-TiAl alloy as an emerging machining technology. In this study, finite element analysis was first used for thermal-electromagnetic coupling analysis to determine the depth of the thermal affected zone and preheating time. Subsequently, the influence of two key parameters, preheating temperature and feed rate, on machining characteristics and surface integrity was investigated, and compared with traditional milling methods. Finally, the fracture mechanism of the gamma-TiAl alloys lamellae was revealed through microstructural analysis. The results indicate that IAM is a promising machining method that can significantly improve the machining performance and surface integrity of gamma-TiAl alloys.