Ultrahard material fabrication through laser assisted processing
Breakthrough Hybrid Machining Technique Revolutionizes Tough Material Processing
A groundbreaking hybrid machining method called Laser-Assisted Turning (LAT) has been developed by researchers at the International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), Hyderabad, India. This innovative technique is set to revolutionize the machining of tough materials like Inconel 625 (IN625), a nickel-based superalloy renowned for its exceptional strength, corrosion resistance, and heat stability but known for being difficult to machine with conventional methods.
The LAT technique addresses these challenges by combining localized laser heating with traditional mechanical cutting. The high-powered laser preheats the material just ahead of cutting, reducing resistance, improving tool life, and delivering smoother finishes. This approach significantly reduces cutting forces and tool wear, while improving surface quality and efficiency [1][2][3][4].
Key features and process details of LAT for machining Inconel 625 include:
- Localized laser heating: A high-power diode laser (up to about 2500 watts) precisely heats the workpiece just before the cutting tool engages. This controlled, localized heating induces thermal softening in the superalloy, making the material easier to cut without affecting the entire workpiece or causing distortion [1][4].
- Mechanical cutting with advanced-coated tools: Immediately after laser heating, a cutting tool—often coated with wear-resistant materials such as Chromium Aluminum Silicon Nitride (CrAlSiN) nanocomposites or tungsten carbide—is used to remove material. The laser softening reduces the cutting resistance, which minimizes tool wear and prolongs tool life [1][3].
- Improved machining outcomes: LAT enables:
- Up to 69% improvement in cutting efficiency (speed and material removal rate).
- Around 46% reduction in tool wear compared to conventional turning.
- Better chip formation and surface finish quality.
- Lower cutting forces and heat generation during machining.
The research, led by Prof Shubhra Ghosh Dastidar and his student Nibedita Ray Chaudhuri, has been published in the Journal of Chemical Information and Modeling and is part of a larger trilogy of research on TAK1 conducted between 2023 and 2025 [1][2][3].
The LAT technique has been integrated into a CNC turn-mill centre with real-time monitoring and customised adapters. It has potential applications in various sectors, including aerospace, nuclear, chemical, and power generation industries, as well as automotive parts, where high performance and reliability are critical [2][3][4].
Meanwhile, a team at the Bose Institute, Kolkata, under the Department of Science and Technology, is studying the question of whether a molecule can show signs of intelligence. The research suggests that proteins like TAK1, crucial to immune responses, inflammation, and cell survival, can display basic, context-driven responses, resembling rudimentary intelligence [5][6]. The study bridges biochemistry and machine learning, a branch of artificial intelligence.
References: [1] [Link to the research paper] [2] [Link to the ARCI press release] [3] [Link to the DST press release] [4] [Link to the Indian Express article] [5] [Link to the Times of India article] [6] [Link to the Bose Institute research article]
- The implementation of the Laser-Assisted Turning (LAT) technique, a fusion of technology and science, holds significant potential for the business sector, particularly in industries like aerospace, nuclear, and automotive, due to its ability to streamline tough material processing with enhanced efficiency and tool life.
- As we advance in technology and the economy, it's intriguing to consider recent studies by the Bose Institute, exploring whether certain molecules could exhibit signs of intelligence, marking a convergence of science and artificial intelligence.
- The groundbreaking LAT method, which revolutionizes the processing of hard-to-machine materials like Inconel 625, could lead to a paradigm shift in the subscription-based service model among businesses, as the technique dramatically improves cutting efficiency and surface finish quality.
- Integrating the Laser-Assisted Turning (LAT) technique into CNC turn-mill centres not only marks a technological milestone but also has profound implications for the economy, as smoother, more efficient production processes can reduce costs and generate greater profits within the business realm.
