CNC machining Inconel
- Exceptional Corrosion and Heat Resistance: Ideal for aerospace and chemical industries.
- Precision：0.001mm
- Fast Turnaround Times: Receive your parts in just 1-7 days
- Certified Quality: ISO9001:2015 and IATF16949 certified processes for top-quality results.
Ensuring 0.001mm Precision in CNC Inconel Machining
At Modo Rapid, we achieve high precision in our machining processes, with tolerances up to ±0.001 mm.
Our commitment to tight tolerances ensures your components meet the strictest standards, crucial for your critical applications.
Inconel Material Selection
Which Inconel alloy is best for my application, and what are the differences between them?
Selecting the right Inconel alloy is essential for optimal performance and durability. Each Inconel type has unique properties suited for specific applications.
What Inconel alloys can I choose?
- Inconel 600: Excellent oxidation and corrosion resistance, suitable for high-temperature and high-stress environments.
- Inconel 601: Outstanding resistance to heat and oxidation, commonly used in thermal processing applications.
- Inconel 625: Superior strength and toughness, ideal for aerospace and marine applications.
- Inconel 718: High strength and corrosion resistance, widely used in the aerospace and oil & gas industries.
- Inconel X-750: Excellent creep-rupture strength, used in high-temperature structural applications.
- Inconel 617: Combines good oxidation and corrosion resistance with excellent high-temperature strength.
How Modo Rapid Ensures Your Inconel Parts Remain Deformation-Free
Inconel is a challenging material to machine. At Modo Rapid, we prioritize your needs and ensure your Inconel parts maintain their integrity throughout the CNC machining process.
Heat Buildup
Inconel alloys generate significant heat during machining, leading to increased tool wear and heat at the contact point. We reduce the CNC machine RPM and use a larger chipload to manage this. Additionally, our high-pressure coolant systems ease the strain on cutting tools, ensuring high-quality Inconel parts for you.
Workholding
Inconel’s toughness requires a firm grip during CNC machining. We maintain a tight hold and ensure constant tool motion without interruptions. This prevents deformation and guarantees that your parts are machined to perfection.
At Modo Rapid, we understand the challenges of machining Inconel and employ expert techniques to ensure your parts remain flawless and deformation-free.
What are the maximum part sizes and complex geometries you can handle?
-
Part Sizes: We can machine parts with maximum dimensions of 1500mm x 800mm x 600mm, meeting the needs of most industrial applications.
-
Complex Geometries: Our 5-axis and 4-axis CNC machining centers can precisely machine complex geometries, including internal channels, intricate surfaces, and high-precision apertures. Our equipment can manage fine features and tight tolerances, ensuring your design intentions are perfectly realized.
What advanced CNC equipment do you have for machining Inconel alloys?
5-Axis CNC Machining Centers: Capable of producing complex geometries and intricate designs, ensuring high accuracy and smooth finishes on Inconel components.
High-Speed CNC Mills: Equipped with robust spindles and high feed rates, ideal for efficiently machining Inconel while maintaining tight tolerances.
Multi-Tasking CNC Lathes: These machines combine milling and turning capabilities, allowing for versatile and efficient production of Inconel parts in a single setup.
Precision CNC Grinders: Essential for achieving the fine surface finishes and exact dimensions required for high-performance Inconel components.
EDM (Electrical Discharge Machining): Utilized for cutting intricate shapes and hard-to-machine areas, providing high precision without inducing stress in the Inconel material.
Mill-turn machine: Combines turning and milling functions in one, completing complex multi-axis machining on a single setup. It improves accuracy and efficiency, ideal for high-precision parts. For Inconel alloy parts, its high rigidity and multi-axis capabilities reduce machining time and ensure quality. Using efficient tools and optimized parameters further enhances production speed and reliability.
Inconel Parts Finishes
Surface Finish Options
- Smoothing
- Polishing
- Bead blasting
- Brushing
- Painting
- Chroming
- Metallizing
- PVD coating
- Powder coating
- Electrophoresis
Impact of Surface Preparation on Inconel Parts
Surface preparation significantly influences both the performance and appearance of Inconel parts:
- Enhanced Durability: Proper surface preparation can increase the lifespan of Inconel parts by improving resistance to corrosion and wear.
- Improved Functionality: A well-prepared surface can reduce friction and improve the efficiency of mechanical components.
- Aesthetic Appeal: High-quality finishes enhance the visual appeal of Inconel parts, making them suitable for both functional and decorative applications.
- Adhesion of Coatings: Proper preparation ensures better adhesion of subsequent coatings or treatments, ensuring consistent and long-lasting finishes.
Inconel Part Surface Finish
Cost Calculation for Custom Inconel Alloy Parts
The cost of machining Inconel parts at Modo Rapid is determined by several key factors:
- Material Costs: The price of Inconel, which is higher compared to other metals, is a significant factor.
- Complexity of Design: Parts with intricate designs and tight tolerances require more time and specialized tools, increasing costs.
- Machining Time: Longer machining times due to Inconel’s hardness and the need for precise operations.
- Surface Finishes: Additional processes such as anodizing, polishing, or coating add to the total cost.
- Tool Wear: Inconel’s toughness leads to faster tool wear, contributing to higher tool replacement costs.
Volume Discounts and Minimum Order Quantity
At Modo Rapid, we offer volume discounts to accommodate larger production runs. The discounts increase with the order size, making it more cost-effective for bulk purchases. We understand the diverse needs of our clients, so we have set a flexible minimum order quantity to cater to both small and large projects.
Example: Cost Calculation
Let’s assume we have an Inconel alloy part with the following specifications:
- Dimensions: 100mm x 50mm x 10mm
- Complexity: Medium complexity geometry
- Surface Finish: Anodized
- Quantity: 50 pieces
Material Cost
- Price of Inconel alloy: $100/kg
- Weight per part: 0.5 kg
- Total material cost: 50 pieces x 0.5 kg x $100/kg = $2,500
Machining Cost
- Machining time for medium complexity parts: 3 hours/part
- Machining rate: $120/hour
- Total machining cost: 50 pieces x 3 hours/piece x $120/hour = $18,000
Surface Finish Cost
- Anodizing cost: $25/piece
- Total surface finish cost: 50 pieces x $25/piece = $1,250
Tool and Equipment Wear
- Inconel alloy causes significant tool wear, requiring frequent replacement
- Estimated tool and equipment wear cost: $750
Other Costs
- Quality control and inspection fees: $600
- Packaging and shipping fees: $300
Total cost = Material cost + Machining cost + Surface finish cost + Tool and equipment wear + Other costs
Total cost = $2,500 + $18,000 + $1,250 + $750 + $900 = $23,400
Cost per part = Total cost / Quantity
Cost per part = $23,400 / 50 pieces = $468/piece
This example provides a rough estimate of the cost. Actual costs will vary based on specific designs, process requirements, and quantities. To receive an accurate quote, please provide detailed mechanical drawings and technical specifications. We will then provide a customized quote based on your needs.
Production Lead Time and Delivery Time
Typical Lead Time from Order Placement to Delivery
At Modo Rapid, our standard lead time from order placement to delivery typically ranges from 1 to 2 weeks. This timeline includes:
- Order Confirmation and Planning: 1-2 days
- Procurement of Materials: 2-3 days
- Machining and Production: 5-7 days
- Quality Control and Inspection: 1-2 days
- Packaging and Shipping: 1-2 days
How Do We Deal With Your Expedited Orders？
Yes, we can shorten the production time for expedited orders. If you require faster delivery, please inform us at the time of order placement. Expedited orders are subject to an additional fee and depend on the current production schedule and the complexity of the parts. By prioritizing your order, we can often reduce the lead time to 1-7 days.
Our team is committed to meeting your deadlines and ensuring that you receive your parts on time, even for urgent projects. Please contact us directly to discuss your specific requirements and expedited options.
How Do We Ensure Consistency and Quality for Each Batch of Parts?
Quality Control Measures:
Advanced Inspection Tools: Utilization of CMMs (Coordinate Measuring Machines), laser scanners, and precision gauges to measure critical dimensions and geometries.
In-Process Monitoring: Continuous monitoring during machining processes to detect and correct deviations in real-time.
Material Verification: Comprehensive material testing, including chemical composition and mechanical property analysis, to ensure conformity with specifications.
Surface Finish Analysis: Employing profilometers and other surface finish measurement tools to guarantee that all parts meet required surface quality standards.
Environmental Controls: Maintaining a controlled environment in production areas to minimize the impact of temperature and humidity variations on machining accuracy.
Ensuring Consistency and Quality for Each Batch:
Standard Operating Procedures (SOPs): Strict adherence to standardized processes for each operation to ensure uniformity across all production stages.
First Article Inspection (FAI): Conducting thorough inspections on the first piece of each batch to verify that it meets all specified requirements before proceeding with full-scale production.
Statistical Process Control (SPC): Applying SPC techniques to monitor and control the manufacturing process, ensuring that variations are kept within acceptable limits.
Lot Traceability: Implementing comprehensive traceability systems to track materials and processes for each batch, allowing for easy identification and resolution of any quality issues.
Final Inspection and Testing: Performing rigorous final inspections and functional tests on all parts before shipment to confirm that they meet client specifications and quality standards.
Our commitment to stringent quality control measures ensures that you receive consistent, high-quality parts in every batch, supporting your projects’ success and reliability.
Why Modo Rapid is Your Trusted Partner for Inconel Projects
At Modo Rapid, we combine extensive experience, advanced technology, and a skilled team to deliver high-quality Inconel parts.
Rich Experience: Over a decade in Inconel machining across aerospace, chemical, and energy industries.
Advanced CNC Technology: Cutting-edge equipment for precision and efficiency in complex geometries.
Skilled Team: Expert engineers and technicians dedicated to quality and overcoming Inconel’s unique challenges.
Stringent Quality Control: Rigorous measures at every stage ensure consistent, reliable parts.
Customer-Centric Approach: Tailored solutions with open communication and collaboration.
Innovative Solutions: Continuous investment in R&D for advanced, competitive solutions.
Client Feedback & Reviews
Ensuring Your Compliance with Environmental and Industry Standards
At Modo Rapid, we prioritize your need for environmentally responsible and industry-compliant manufacturing processes.
Meeting Your Environmental and Industry Standards: Our operations are designed to align with stringent environmental and industry regulations, ensuring that your projects not only meet but exceed these standards.
Certifications That Matter to You:
- ISO 9001: Guaranteeing consistent quality and continuous improvement in every product you receive.
- ISO 14001: Demonstrating our commitment to environmental management, so you can trust our sustainable practices.
- RoHS Compliance: Ensuring our materials are free from hazardous substances for your safety and peace of mind.
- REACH Compliance: Managing chemicals responsibly in our products to meet your regulatory requirements.
- IATF 16949: Meeting the rigorous quality management standards required for the automotive industry, ensuring the highest quality for your automotive projects.
FAQ
Machining Inconel is quite challenging due to its toughness, high strength, and low thermal conductivity. These properties lead to significant heat buildup and rapid tool wear, making it harder than many other materials.
Inconel has poor machinability compared to most metals. It requires specialized tooling, slower cutting speeds, and high-pressure coolant to manage the heat and maintain tool life. It’s known for causing wear and tear on cutting tools.
Inconel 718 is particularly tough due to its high strength and the presence of hardening elements like nickel and chromium. It maintains its strength at high temperatures, which makes it harder to cut and causes quicker tool wear.
The cutting speed for Inconel is typically lower than for other metals, ranging from 30 to 50 meters per minute (m/min). Keeping speeds low helps manage the heat and extend tool life.
The main disadvantages of Inconel are its high cost, difficulty in machining, and rapid tool wear. Additionally, its low thermal conductivity leads to significant heat buildup during machining.
Yes, carbide tools can cut Inconel, but they need to be high-quality and properly coated, such as with TiAlN (Titanium Aluminum Nitride), to withstand the heat and wear.
Monel is easier to machine than Inconel. Monel has a higher nickel content but lacks the same level of high-temperature strength and hardness found in Inconel. This makes Monel less demanding on tools and cutting speeds.
Inconel can crack due to stress, particularly when it’s subjected to high temperatures and mechanical loads. Improper machining or welding can also introduce cracks due to thermal stress.
Inconel typically does not require passivation like stainless steel because it’s already highly resistant to corrosion. However, cleaning and surface treatments may still be necessary depending on the application.
There is no direct evidence to suggest that Inconel is cancerous. However, like many metals, fine particulates or fumes generated during machining or welding should be managed with appropriate safety measures to avoid inhalation and health risks.
Yes, Inconel is hard to weld due to its tendency to crack and its high-temperature strength. Proper techniques and filler materials are essential to achieve good weld quality.
Inconel alloys are composed of a blend of chromium, nickel, iron, molybdenum, and other alloying elements.
Kennametal’s KCSM15A coating performs well in high-temperature alloys, often improving tool life by 20 to 40 percent.
High-efficiency or dynamic toolpaths are recommended, particularly when cutting depths are two to three times the tool diameter.
Kennametal’s HARVI III, KOR6 DT, and high-density end mills like RSM II are recommended for high-efficiency machining applications.
Solid carbide tools, especially those with silicon-enhanced coatings, significantly increase tool life and efficiency in machining Inconel and other heat-resistant superalloys.
Silicon coatings enhance wear resistance and combat the abrasiveness of Inconel, resulting in increased tool life.
Guhring’s RF 100 “Speed” family of end mills, including the five-flute (5-Speed) and seven-flute (7-Speed) options, are recommended for high-speed milling.
Use high-speed milling techniques with deeper depths of cut, lighter widths of cut, and multi-fluted tools to gently peel the material away.
Using coolant-through tools with high-pressure coolant (at least 500 psi) is crucial for effective drilling and milling of Inconel to avoid work-hardening and ensure proper chip evacuation.
Avoid peck drilling in Inconel to prevent work-hardening and ensure smooth drilling operations.
Inconel work-hardens quickly, so using coolant-fed drills and avoiding peck drilling are essential to prevent tool damage and maintain efficiency.
Custom Inconel Parts for Your Project!
Experience tailored excellence with our high-precision Inconel parts. We manufacture to your exact specifications, ensuring top-quality results and cost efficiency.
At Modo Rapid, we prioritize your project’s success, offering unmatched precision and competitive prices. Choose us for seamless, customized Inconel part solutions. Send us your specifications and let us help you achieve your goals.
Get a quote for custom titanium parts
