Super duplex stainless steels (SDSS) are extensively employed in marine, nuclear, oil and
petrochemical sectors owing to their high mechanical strength and corrosion resistance. While
manufacturing these SDSS components, machining operations play a crucial role in achieving
the desired shape and dimensions. However, factors such as low thermal conductivity, work
hardening combined with built-up edge formation make it a difficult-to-machine material. In
addition, during machining, the high temperature in the machining zone accelerates the tool wear
leading to a decreased tool life. These aspects can negatively influence the surface integrity of
the component and generate high tensile residual stress on the machined component’s surface.
When this machined SDSS component with more tensile stress is exposed to the aggressive
chloride environment, it leads to the formation of stress corrosion cracks (SCC). Stress corrosion
cracking is an environmental assisted form of corrosion, which leads to catastrophic failure of
parts and components. The developed cracks are difficult to visualize and damage cannot be
easily predicted. Hence, the study to improve stress corrosion cracking resistance of SDSS
machined components is necessary to avoid these failures. This work focusses on determining
the efficient machining strategy to improve the machinability and surface integrity of SDSS,
thereby reducing the harmful tensile stress and improving the stress corrosion cracking
resistance. In order to understand the effect of machining induced residual stress on the SCC
behaviour, the machined SDSS specimens were subjected to SCC test in chloride environment
and their cracking behaviour were analysed in detail. To enhance their SCC resistance,
multilayer coatings on cutting tools, dry, flood and Minimum quantity lubrication (MQL)
coolants are the strategies investigated during machining. This work also includes finite element
(FEM) based numerical models (Coupled Eulerian-Lagrangian approach) for residual stress
prediction in 3D orthogonal cutting to estimate the service life of the machined component.