Nickel based superalloys, such as Waspaloy, are extensively used for applications under heavy environmental conditions due to their superior thermo-mechanical properties. However, manufacturing processes of these materials are challenging since they involve issues related to their poor workability. Thus, huge research work for optimizing the processing parameters is still required. This problem becomes even more pronounced when finishing processes, such as roller burnishing, are considered. In fact, it is crucial to use parameters able to increase the productivity and to improve the quality of the manufactured parts, consequently a huge number of preliminary experimental tests have to be carried out. Hence, numerical simulation can be a valid support for obtaining information about the metallurgical phenomena that affect the materials while large strains occur. However, commercial software are not still able to appropriately predict such modifications. Thus, the main objective of the present work is to study a roller burnishing on Waspaloy in terms of processing parameters and surface integrity by experimental and numerical analysis, in terms of forces, temperatures, roughness, microstructural modification and microhardness. Thus, the customized simulation demonstrated to provide useful information able to drastically reduce the number of needed tests leading also to a deeper knowledge of the microscopic phenomena involved in the process.
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