Analysis Report on Difficult-to-Machine Materials and Mainstream Applications

I. High-Difficulty Machining Materials

1. Nickel-based Superalloys

• Representative Materials: Inconel 718, Waspaloy, Hastelloy
• Machining Difficulties:
  • High temperature strength
  • Severe work hardening
  • Poor thermal conductivity
  • High tool adhesion tendency
• Main Applications: Aircraft engines, Gas turbines

2. Titanium Alloys

• Representative Materials: Ti-6Al-4V, Ti-5553
• Machining Difficulties:
  • High specific strength
  • Low elastic modulus
  • High chemical reactivity
  • Poor thermal conductivity
• Main Applications: Aerospace, Medical implants

3. High-Temperature Steel Alloys

• Representative Materials: H13, D2, M42
• Machining Difficulties:
  • High hardness
  • High toughness
  • High cutting temperatures
• Main Applications: Mold manufacturing, Tool making

4. Composite Materials

• Representative Materials: Carbon Fiber Composites (CFRP), Glass Fiber Composites
• Machining Difficulties:
  • Anisotropic properties
  • Risk of delamination
  • Fiber breakage issues
• Main Applications: Aerospace, Automotive industry

II. Current Mainstream Materials

1. Medical Field

• Cobalt-Chromium-Molybdenum Alloys
  • Good biocompatibility
  • High corrosion resistance
  • Mainly used for artificial joints
• Medical Titanium Alloys
  • Lightweight
  • Excellent biocompatibility
  • Used for implants

2. Aerospace Field

• High-Strength Aluminum Alloys
  • 7075, 2024 series
  • Light weight, high strength
  • Used for airframe structures
• High-Temperature Alloys
  • PM-X series
  • Heat resistant, fatigue resistant
  • Used for engine components

3. Mold Industry

• Pre-hardened Mold Steel
  • NAK80, 718H
  • Good machinability
  • Used for plastic molds
• Powder Metallurgy Tool Steel
  • ASP23, M4
  • Good wear resistance
  • Used for precision stamping dies

4. New Energy Industry

• High Conductivity Copper Alloys
  • Good electrical conductivity
  • Excellent heat dissipation
  • Used for power batteries
• Rare Earth Permanent Magnetic Materials
  • Excellent magnetic properties
  • Difficult to machine
  • Used in motor manufacturing

III. Future Development Trends

1. Lightweight Materials

• Aluminum-lithium alloys
• Magnesium alloys
• High-strength composites

2. Special Functional Materials

• Shape memory alloys
• High-temperature superconductors
• Smart materials

3. Eco-friendly New Materials

• Biodegradable materials
• Recycled materials
• Low-carbon materials

IV. Machining Recommendations

1. General Machining Strategies

• Select appropriate tool materials and coatings
• Optimize cutting parameters
• Implement efficient cooling technology
• Plan reasonable machining paths

2. Special Processing Measures

• Ultrasonic-assisted machining
• Cryogenic machining technology
• High-pressure cooling technology
• Dry machining technology

V. Conclusion

Currently, difficult-to-machine materials mainly include:

1. Heat-resistant alloys
2. Titanium alloys
3. High-hardness steels
4. Composite materials
5. Special functional materials

The application of these materials is becoming increasingly widespread, requiring continuous optimization of machining processes and development of new processing technologies.