International Research Journal of Education and Technology

Nickel-based additive manufacturing (AM) is revolutionizing aerospace by enabling the production of high-performance components with complex geometries and superior high-temperature properties. While these superalloys are critical for demanding environments, their machining presents challenges due to high strength, low thermal conductivity, and rapid work hardening. Near-net shape production minimizes material waste and post- machining effort, while advanced cutting tools, optimized parameters, and cooling techniques improve machining efficiency. Hybrid manufacturing combines AM and subtractive processes to achieve precision and surface quality. This integration makes nickel-based AM a vital technology for aerospace innovation.

Key Words: Nickel-based additive manufacturing (AM), aerospace applications, machining characteristics, high- performance components, complex geometries, high- temperature properties, work hardening, tool wear, cooling techniques, hybrid manufacturing.