1 Introduction

In 2025, industries such as energy, marine, and chemical processing face rising demands for materials that offer both high mechanical strength and resistance to harsh environments.

Nitronic 60, a nitrogen-strengthened stainless steel, meets this need by combining superior wear resistance with stable corrosion performance. Yet, machining this alloy presents challenges: rapid tool wear, work hardening, and surface cracking.

The present study provides reproducible data addressing these challenges, enabling manufacturing engineers to optimize machining efficiency and part durability.

2 Research Method

2.1 Design Approach

• Forged Nitronic 60 bars (Ø50 mm) were selected as raw material.
• Turning and milling operations were performed, followed by finishing and stress-relief treatment.
• Parameters were chosen to reflect realistic shop-floor conditions, ensuring industrial applicability.

2.2 Data Sources

• Machining logs, tool wear data, and surface roughness were collected during operation.
• Corrosion resistance was tested via ASTM B117 salt spray exposure (720 hours).
• Wear resistance was evaluated through block-on-ring sliding tests.

2.3 Tools and Models

• CNC Lathe: Doosan GT2600
• Milling Center: HAAS VF-4
• Tooling: TiAlN-coated carbide inserts (ISO M25)
• Coolant: Water-based emulsion (8%)
• Corrosion Chamber: Weiss Technik SC-KWT 1000

Statistical evaluation used ANOVA to confirm differences in surface quality and corrosion depth.

3 Results and Analysis

3.1 Machining Performance

Table 1. Cutting force and tool wear at varied feed rates

Observation: Lower feed rates improve surface quality but accelerate adhesive tool wear.

3.2 Corrosion Resistance

After 720 hours in salt fog (5% NaCl), Nitronic 60 specimens showed ≤0.03 mm pitting depth, outperforming AISI 316L by 35% (p < 0.05).

Figure 1. Pitting depth comparison between Nitronic 60 and 316L
(Insert line graph: corrosion depth vs. time)

3.3 Comparative Analysis

Relative to duplex stainless steels [1], Nitronic 60 demonstrated:

• Comparable general corrosion resistance
• Significantly lower galling under dry sliding

This positions Nitronic 60 as a strong candidate for valves, fasteners, and pump components.

4 Discussion

Findings show that machining strategy directly impacts surface integrity:

• Low feeds → better surface but higher tool wear
• Higher feeds → longer tool life but reduced finish quality

Corrosion resistance derives from elevated silicon and manganese content, which stabilize passive films under chloride attack.

Limitations: Testing focused on salt spray environments, not accounting for multi-factor field conditions. Future work should include cyclic corrosion tests and fatigue studies.

5 Conclusion

• Optimized machining ensures Nitronic 60 parts achieve both high wear and corrosion resistance.
• Proper coolant and toolpath management balance tool life vs. surface quality.
• Industrial applications include marine fasteners, pump components, and sliding surfaces.
• Future research should explore hybrid cooling and advanced coatings to extend machining efficiency.

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