Machining Inconel: How CAMM Metals Excels in Handling This Challenging Aerospace Material

Inconel is a nickel-based superalloy that is prized for its strength, corrosion resistance, and ability to maintain its properties in extreme environments. But there’s one reason a lot of shops shy away from it: machining Inconel is extremely challenging. 

Anyone who has experience working with this material knows it is not for the faint of heart. However, at CAMM Metals, we have been successfully cutting and machining Inconel components for decades. Large aerospace OEMs like Pratt & Whitney trust us to manufacture parts made from this notoriously difficult material, including parts that live on the back of the F-22! 

Why Inconel Is So Challenging 

Photo credit: U.S. Air Force (USAF)

Inconel’s biggest strength is also its biggest challenge. It’s designed to withstand heat and pressure, which means it doesn’t like to move, deform, or cut easily. The material is tough on tooling and equipment, and even tougher on the teams running the machines. Every setup needs to be precise and every move planned carefully, especially when the material itself is so expensive. 

That’s where experience comes in. At CAMM Metals, we understand that working with tough alloys like Inconel requires a learning curve and even some trial and error. We spent years learning how to overcome challenges and how best to work with Inconel and other aerospace materials. From managing tool wear to optimizing feed rates and fixture design, our team knows exactly what it takes to get successful results from such a demanding material. 

The Role of Our Waterjet Cutting Services in Machining Inconel 

When it comes to working with exotic materials like Inconel, our waterjet cutting expertise is one of our biggest advantages. Waterjet cutting is a cold process, which means it doesn’t create a heat-affected zone that could alter the material’s properties. This is crucial when working with aerospace-grade materials that can’t afford any physical changes. 

But waterjet cutting isn’t a simple process. It requires a deep understanding of the equipment, the material, and even the water itself. When a waterjet pierces material, it’s pushing water at 30,000 to 40,000 psi; that’s enough force to move parts if they’re not properly fixtured. Over the years, we’ve developed reliable processes to manage turbulence, minimize movement, and ensure consistent, precise results. 

Some Inconel parts we cut can have a four-hour run time, which means there’s zero room for error. Between the high cost of the material and the time on the machine, everything has to be right the first time. Fortunately, our team has decades of experience fine-tuning those setups, so customers know their parts are in capable hands. 

Secondary operations and high-precision work

After waterjet cutting, many Inconel parts need follow-up work. Depending on the design, we might drill and ream holes for tighter tolerances, or finish edges to exact specifications. Our team handles these capabilities in house to maintain control over quality and consistency. 

Our combination of equipment and expertise allows us to deliver custom fabricated components that meet the most demanding standards in the aerospace and defense sectors. 

Trusted by Aerospace Leaders for a Reason 

Many fabrication shops don’t want to take on Inconel components because of the cost and learning curve. But at CAMM Metals, we’ve already done the hard work. We’ve established proven processes, refined our approach, and developed the in-house expertise to handle tough materials. 

Are you interested in learning more about our experience machining Inconel and other exotic materials? Request a quote from CAMM Metals to find out how our expert team can support your next project.