A sustainable approach for the preparation and stability of mono and hybrid nanofluids in the milling of Nickel based superalloy

This work is focused on enhancing the sustainability and machinability in finish end-milling of Nimonic 90 superalloy using nanofluid-assisted machining. The research deals with the preparation and analysis of the stability of hybrid nanofluids for the machining of Nimonic 90. The UV-visible absorption of prepared mono and hybrid nanofluids are examined and based on the absorption curves, and 1% of the weight of the nanoparticles is chosen. The samples have been used to estimate the ideal ultrasonication time and its behaviour with various ionic and non-ionic surfactants have been determined. By examining the UV-visible absorption curves, the shelf life of the hybrid nanofluid is obtained, and it is found to be equivalent to that of the freshly prepared nanofluid. When preparing nanofluids based on alumina and hBN, tween 80 and Sodium Dodecyl Sulfate (SDS) has proved to be to be superior surfactants, respectively. Furthermore, toxicity test has revealed that the well-dispersed nanofluid are non-toxic in nature, with hybrid nanofluid exhibiting 84% cell viability. The hybrid nanofluid possesses a zeta potential of-30.8 mV. Additionally, has been observed that all the prepared nanofluids exhibited Newtonian behaviour and that their viscosities are 15%-20% higher than those of the base fluid. During the nanofluid assisted machining with hybrid nanofluid, the machining results of Nimonic 90 superalloy demonstrate the synergistic influence of both nanoparticles. Compared to dry machining, the hybrid nanofluid has a 48.80% reduction in cutting forces, 72.66% reduction in cutting temperature, 63.63% reduction in surface roughness, and 46.03% reduction in flank wear. Additionally, a Pugh matrix assessment score of 9 compared to the score of-5 for dry machining indicates that the usage of hybrid nanofluid as a cutting condition has substantial potential for future sustainable machining methods.