Machining Waspaloy: The Fiercest Super Alloy You've Never Seen

Witness the ultimate test of machining skill as Tyson from Titans of CNC takes on Waspaloy, one of the nastiest, most unforgiving materials on the planet. This rare super-alloy can destroy tools and drain your wallet in seconds. Watch Tyson battle through broken tools and near disasters to uncover the secrets of mastering this beast. Only the top 0.001% of machinists dare to attempt this—can Tyson conquer Waspaloy? Click to find out!

00:00 What is Waspaloy
01:10 Tool 1 of CNC Machining Waspaloy (Breaking an Insert)
03:11 Finishing Pass of the OD
03:59 Threading Waspaloy
05:25 Parting Waspaloy and Transfering to Side 2
08:33 Roughing and Facing Passes of the Bolt (Clever Trick to CNC Machine This)
11:10 Time for Tyson to do MILLING Ops
12:27 Haimer Shrink Fitting Tool
13:00 CNC Machining the Star Bolt Pattern
15:27 Behold the Aerospace Waspaloy Bolt

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[Erik-rphi]

I work for HiShear an aerospace fastener co. They do large lots for Boeing and Airbus. For big bolts like this one they would invest in tooling to Hot stamp the head, grind the shank, hot roll the thread after heat treating. Maybe also roll radius or Roll Burnishing the head/shank radius for higher strength. Then the part goes to plating for what ever is called out.

[markconroy]

I have machined this material a few times before and the knowledge you gain on the manual machine really helps the speeds and feeds for when you need to program a CNC !

[glennjames]

I used to weld Waspalloy, Inconel, Monel, and a lot of other aircraft engine alloys. I worked for a company called Chromalloy which was an FAA lic. repair station. We reconditioned hot section parts and combustion chambers for a large variety of commercial aircraft engines. I worked mostly on JT-9D Pratt and Whitney parts, and GE LM-2500 parts.

[MrWhatnext]

I used to run this stuff on a turret lathe many years ago. We used cutting oil, low rpm and heavy feeds. Sharp tools are a must.

[JWimpy]

That is one really expensive bolt.
CNC machines always amaze me. And what is even more amazing are the machinists that program the setup of a part.

[mw]

I used to turn Waspaloy to make high performance bolts for F1.

[Hydrazine]

Nickel based superalloy with, let's see, 18-21 % chromium, which is ok, 12-15 % cobalt, which is YIKES!, a significant 3.5-5 % molybdenum for increased corrosion resistance, around 3% titanium and about 1.5% aluminium, to form intermetallics (it is age-hardening), a few knife tips of carbon, boron and zircon, and the rest is incidental, so only a max. value, not a minimum required concentration.

Yeah, I don't need to _see_ this alloy (congrats, you guys are the first to show it to me!) because the chemical composition tells it all. This is one nasty mother trucker!

[sminkles]

I had the pleasure of turning this on a big DSG lathe. A special "one off "for an oil company. It certainly was a massive learning curve for me!!

[TheSMPeto]

I'm literally VTL turning a Waspaloy turbine disk now... Using a 3/8 button since I don't have to get into any tight corners. The bigger radius will last longer, for anyone that may need to know.. also a lesser depth of cut helps a ton too, but I'm using a totally different composition of insert, so I may have to order up a 433 like this guy is using. Good stuff!

[trevorgoforth]

Nice work Tyson! Thanks for taking us through the entire process!

[alteredfatez]

Great video. Mechanical work of art. Love your programming explanations.

[Dillybar]

YES MORE TYSON! THE RETURN OF THE KING!

[AVATARComander]

I learned about this stuff from my parents on an awesome take your kid to work day. Turbo machinery is very interesting

[precisiond]

Machined this decades ago, at Boeings real machine shop, for the space shuttle engines.

[opendstudio]

The pain shows up when attempting to bore and thread smaller diameter features on super alloys.

[rowanhaigh]

As someone who knows nothing about machining and manufacturing, I found this completely entrancing.❤

[hindleygj]

I don't think I've ever subscribed so fast to someone's channel.

[larryblount]

I am amazed that a part stick out thatvfar did not cause tool chatter. That wasp metal is tuff stuff. I expect the aluminum was more of a challenge in the prototyping and used for filming purposes.
Thank you for the VIDEO.

[ctc]

Its cool to see things being made with this alloy i worked at a foundry making these types of alloy (wasp, hastelloy x, 718 etc) for 15yrs

[drokles]

I have heard stories from my coworkers about how some gas turbine blades we make sometimes for Siemens and they are made of that stuff. The machine that runs it shakes so much when it begins to mill that you can feel the vibrations in the floor on the other side of the factory floor. We haven’t made them while I have worked there though so i can’t say if it is true or not but maybe someday I’ll see it for myself