Surface integrity is a critical aspect of machining nickel-based alloys due to their applications in critical components and employment in a harsh environment. The development of sustainable methods for machining difficult-to-cut materials is now of utmost importance because of global environmental concerns, strict policies, and diminishing natural resources. Consequently, different sustainable machining techniques have been developed and utilized for characterizing surface integrity. In the present study, the application of ultrasonically atomized cutting fluid (UAF) has been employed for machining nickel alloys, and its influence on the surface integrity has been evaluated. Moreover, the performance of UAF process has been compared with previously existing machining techniques. The experimental study includes measurement of microhardness, residual stresses, surface topography, chip morphologies, and microstructural changes. The ${\mathit{sin}}^2\psi -\sin 2\psi$ technique of X-ray diffraction (XRD) is utilized for evaluating residual stresses, whereas microstructural analysis is performed using electron back scattering diffraction (EBSD). It has been found that different lubrication techniques reduces the surface hardening phenomenon by restraining the plastic deformation. Tensile residual stresses have been achieved in dry machining and MQL processes, while flood cooling and UAF processes resulted in compressive residual stresses. MQL and UAF processes have been found to result in less misorientation and grain redistribution as compared to dry and flood cooling. Overall, the UAF process has been found to result in improved surface integrity which enhances the product life and performance.

由于镍基合金在关键部件中的应用和在恶劣环境中的应用，表面完整性是加工镍基合金的一个关键方面。由于全球环境问题、严格的政策和日益减少的自然资源，开发加工难切削材料的可持续方法现在至关重要。因此，已经开发并使用了不同的可持续加工技术来表征表面完整性。在本研究中，超声雾化切削液 (UAF) 已用于加工镍合金，并评估了其对表面完整性的影响。此外，UAF 工艺的性能已与现有的加工技术进行了比较。实验研究包括显微硬度的测量，残余应力、表面形貌、芯片形态和微观结构变化。这${\mathit{罪}}^2\psi -\mathrm{罪}2\psi$X射线衍射（XRD）技术用于评估残余应力，而微观结构分析则使用电子背散射衍射（EBSD）进行。已经发现，不同的润滑技术通过抑制塑性变形来减少表面硬化现象。在干式加工和 MQL 工艺中已经实现了拉伸残余应力，而溢流冷却和 UAF 工艺导致了压缩残余应力。与干冷和洪水冷却相比，已发现 MQL 和 UAF 工艺导致更少的取向错误和晶粒重新分布。总体而言，已发现 UAF 工艺可改善表面完整性，从而提高产品寿命和性能。