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Crystal-packed, honeycomb-like, and partially developed spherical particles constituted of small crystals have been found in chips yielded in high-speed machining of alloy steel AerMet100. Scanning electron microscopy and X-ray energy dispersive spectroscopy examination of the chips were carried out to investigate the formation mechanism of the spherical particles. Results show that, depending on chip size and shape, chip melting completeness changes greatly, and the solidification process of the melted chips and the final microstructure of the spherical particles are controlled by heat dissipation rate.

Microstructure of spherical particles generated in high-speed machining of an alloy steel