AU2021206812B1 - Method for Internal Stress Regulation in Superalloy Disk forgings by Pre-spinning - Google Patents
Method for Internal Stress Regulation in Superalloy Disk forgings by Pre-spinning Download PDFInfo
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- 238000005242 forging Methods 0.000 title claims abstract description 282
- 238000009987 spinning Methods 0.000 title claims abstract description 195
- 238000000034 method Methods 0.000 title claims abstract description 48
- 229910000601 superalloy Inorganic materials 0.000 title claims abstract description 29
- 230000001105 regulatory effect Effects 0.000 claims abstract description 37
- 229920003023 plastic Polymers 0.000 claims abstract description 26
- 238000012544 monitoring process Methods 0.000 claims abstract description 12
- 238000009826 distribution Methods 0.000 claims description 47
- 238000010438 heat treatment Methods 0.000 claims description 42
- 238000012360 testing method Methods 0.000 claims description 18
- 230000001965 increasing effect Effects 0.000 claims description 14
- 238000010586 diagram Methods 0.000 claims description 8
- 230000003247 decreasing effect Effects 0.000 claims description 6
- 238000004364 calculation method Methods 0.000 claims description 4
- 239000000843 powder Substances 0.000 claims description 4
- 101150108455 Sil1 gene Proteins 0.000 claims 1
- 208000012886 Vertigo Diseases 0.000 description 159
- 238000003754 machining Methods 0.000 description 15
- 238000004088 simulation Methods 0.000 description 10
- 230000000694 effects Effects 0.000 description 9
- 239000000463 material Substances 0.000 description 7
- 229920000426 Microplastic Polymers 0.000 description 4
- 238000002441 X-ray diffraction Methods 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 230000005489 elastic deformation Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 230000001276 controlling effect Effects 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000002224 dissection Methods 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000002035 prolonged effect Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000005856 abnormality Effects 0.000 description 1
- 230000002238 attenuated effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
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Abstract
The present application relates to the field of superalloy, disclosing a method for internal
stress regulation in superalloy disk forgings by pre-spinning. The method includes: Step S1,
determining a target revolution for regulating internal stress in the disk forgings, and
determining a target deformation magnitude of plastic deformation required for regulating
the internal stress by the pre-spinning of the disk forgings; and Step S2, performing the
pre-spinning of the disk forgings by the target revolution, monitoring a deformation
magnitude of the disk forgings, and stopping the pre-spinning when a monitored
deformation magnitude of the disk forgings reaches the target deformation magnitude.
Description
Method for Internal Stress Regulation in Superalloy Disk forgings by Pre-spinning
Description
Technical Field
[0001] The present application relates to the field of materials, in particular to a method
for internal stress regulation in superalloy disk forgings by pre-spinning.
Background Art
[0002] The hot-end turning parts of aero-engine are mainly made of superalloy, including
high-pressure and low-pressure turbine disks, compressor disks, middle-seal disks, etc. In
order to obtain the predetermined mechanical properties on these superalloy disk pieces, it
is necessary to perform organizational regulation on the forgings with a highly precisely
controlled heat treatment system. In the heat treatment procedure, when the required
mechanical properties are obtained, certain internal stress is inevitably introduced to the
disk piece. The heat treatment stress on the forgings can be gradually released in the
subsequent procedures of part machining, surface treatment, and machine service.
[0003] Excessive internal stress level can cause a relatively large deformation to a disk
piece in machining, making it difficult to achieve a predetermined precise dimension on the
part. At the same time, excessive and improperly distributed internal stress will degrade the
dimensional stability of the members and parts in the service procedure, affecting the
engine efficiency or evening causing a failure. Therefore, effective regulation of the heat
treatment internal stress on a forgings is the premise and foundation for ensuring the
dimensional stability of rotor disks during machining and service.
Summary
[0004] The present application proposes a method for implementing a high-speed spinning
treatment on disk forgings, namely acquiring a predetermined micro plastic deformation on
the disk forgings by using centrifugal force load, to effectively regulate and control the stress
distribution state in the disk forgings on the premise of not influencing the subsequent machining and service performance of the disk forgings. According to the method, excessive internal stress formed in the heat treatment procedure can be fully released, so as to avoid the occurrence of harmful deformation of the disk forgings in subsequent part machining procedure. Moreover, the internal stress distribution can be regulated and optimized concerning the service working conditions of the disk forgings, so as to ensure that the disk forgings do not suffer from a harmful deformation under 115% or 120% high-stress state during a procedure of a part over-spinning test, while having a long-term dimensional stability in service on a machine. The method includes a spinning operation performed on the disk forgings after heat treatment and before part machining, and thus is called billet disk pre-spinning. It is a novel technology, aiming at the disk forgings, for actively regulating the internal stress by inducing micro plastic deformation to disk forgings by a rotary centrifugal force.
[0005] In order to achieve the above object, the present application provides a method for
internal stress regulation in a superalloy disk forging by pre-spinning. The method includes:
Step S1, determining a target revolution for regulating internal stress in the disk forgings,
and determining a target deformation magnitude of plastic deformation required for
regulating the internal stress by the pre-spinning of the disk forgings; and Step S2,
performing the pre-spinning of the disk forgings by the target revolution, monitoring the
deformation magnitude of the disk forgings, and stopping the pre-spinning when a
monitored deformation magnitude of the disk forgings reaches the target deformation
magnitude.
Preferably, Step S1 includes: Step S11, obtaining a predicted revolution for regulating the
internal stress in the disk forgings by simulated calculation; Step S12, performing the
pre-spinning of the disk forgings by the predicted revolution, and monitoring the
deformation magnitude of the disk forgings; and Step S13, adjusting the predicted
revolution according to a monitored deformation magnitude of the disk forgings to
determine the target revolution.
[0006] Preferably, Step S13 includes: Step S131, determining the predicted revolution as
the target revolution if the monitored deformation magnitude of the disk forgings reaches the target deformation magnitude when performing the pre-spinning of the disk forgings by the predicted revolution; or Step S132, if the monitored deformation magnitude of the disk forgings is lower than the target deformation magnitude when performing the pre-spinning of the disk forgings by the predicted revolution, gradually increasing the revolution of the pre-spinning until the monitored deformation magnitude of the disk forgings reaches the target deformation magnitude when performing a final revolution of pre-spinning, and determining the final revolution as the target revolution.
[0007] Preferably, Step S132 includes: gradually increasing the revolution of the
pre-spinning by a step of 25-100 rotations per minute if the monitored deformation
magnitude of the disk forgings is lower than the target deformation magnitude when
performing the pre-spinning of the disk forgings by the predicted revolution.
[0008] Preferably, Step S11includes: Step S111, simulating heat treatment of the disk
forgings to obtain a internal stress distribution of the disk forgings; and Step S112, simulating
the pre-spinning of the disk forgings by different revolutions to determine the predicted
revolution, in which the pre-spinning by the predicted revolution enables the internal stress
in the disk forgings to be regulated to be 400MPa or below and enables the residual
deformation magnitude of the disk forgings to be 0.05%-1.95%.
Preferably, Step S111includes: obtaining a internal stress distribution of the disk forgings
after heat treatment by detecting an actual internal stress in the disk forgings and correcting
a simulation result of the disk forgings by using the actual internal stress.
[0009] Preferably, Step S3 is further included: drawing a internal stress distribution diagram
of the disk forgings after pre-spinning. Preferably, Step S3 includes: Step S31 simulating the
pre-spinning of the disk forgings by the target revolution to obtain the internal stress
distribution of the disk forgings after the pre-spinning; and Step S32: detecting an actual
internal stress at a feature site of the disk forgings, and correcting a simulated result of the
disk forgings after pre-spinning by using the actual internal stress to obtain the internal
stress distribution of the disk forgings after pre-spinning;
[00010] Preferably, the target deformation magnitude is 0.05%-1.95%.
[00011] Preferably, the deformation magnitude of the disk forgings is monitored after
keeping a current revolution for at least 30 seconds when performing the pre-spinning.
[00012] Preferably, when monitoring the deformation magnitude of the disk forgings, a
stable value is taken as the monitored deformation magnitude of the disk forgings; and/or
Step S2 includes: gradually decreasing the revolution of the pre-spinning to zero when it is
monitored that the deformation magnitude of the disk forgings reaches the target
deformation magnitude.
[00013] Preferably, the superalloy is a wrought superalloy, a powder superalloy, or a cast
superalloy.
[00014] Preferably, the disk forgings is a disk structure without obvious stress concentration
before pre-spinning, and the disk forgings includes annular disk forgings, compressor disk
forgings and turbine disk forgings.
[00015] Preferably, the operating temperature of the pre-spinning is -50°C-750°C.
[00016] Preferably, the method performs the pre-spinning by a high-speed spinning test
platform and a matched tool for positioning the disk forgings on the high-speed spinning test
platform.
[00017] According to the technical solution, the internal stress within the disk forgings can
be effectively regulated, while the mechanical property of the disk forgings is maintained.
Therefore, the deformation degree of subsequent part machining can be alleviated so as to
shorten the part machining period and reduce the cost. No harmful deformation occurs in
subsequent overspeed test and service life of the machined part, and thus the dimensional
stability of the part can be guaranteed. By forming internal stress distribution beneficial to
the working condition of the disk piece after the pre-spinning, compressive stress is placed
into the hub, and the fatigue life of the disk piece can be effectively prolonged.
Brief Description of the Drawings
[00018] FIG. la is a schematic structural diagram in which disk forgings is a turbine disk, and
FIG. lb is a schematic structural diagram in which disk forgings is an annular disk (for the purpose of showing a cross section, FIG. la and FIG. lb are views with a portion removed, and the disk forgings are of a complete annular shape);
[00019] FIG. 2a to FIG. 2c respectively simulate internal stress distribution states in different
heat treatment process parameters according to Example 1 of the present application, in
which: FIG. 2a is a state in a low internal stress level: the maximum tensile stress in the
central region of the cross section of the disk forgings is 286MPa; FIG. 2b is a state in a
medium internal stress level: the maximum tensile stress in the central region of the cross
section of the disk forgings is 517MPa; and FIG. 2c is a state in a low internal stress level: the
maximum tensile stress in the central region of the cross section of the disk forgings is
681MPa;
[00020] FIG. 3a to FIG. 3d simulate distribution states of the stress and deformation of a disk
forgings during pre-spinning under 0 internal stress condition according to a method of the
present application, in which: FIG. 3a shows a Von mises equivalent stress distribution state
in the disk forgings when reaching a maximum spinning speed; FIG. 3b shows a distribution
state of chordwise internal stress in the disk forgings after the spinning is stopped; FIG. 3c
shows Vonmises equivalent plastic strain distribution in the disk forgings after the spinning is
stopped; and FIG. 3d shows a chordwise component of the residual plastic strain after the
spinning is stopped;
[00021] FIG. 4a to FIG. 4f shows a stress and strain distribution of a disk forgings during
pre-spinning under a condition of superimposed heat treatment internal stress stimulated
according to a method of the present application, in which: FIG. 4a shows a Vonmises
equivalent stress distribution in a disk forgings with medium heat treatment stress when
reaching a maximum spinning speed; FIG. 4b shows a chordwise stress distribution in the
disk forgings with medium heat treatment stress when the spinning speed is maximum; FIG.
4c shows a Vonmises equivalent stress distribution in the disk forgings after the spinning is
stopped; FIG. 4d shows a chordwise stress component after the spinning is stopped,
transited from a compressive stress of -250MPa at an inner diameter to a tensile stress of
150MPa at an outer diameter; FIG. 4e shows a Vonmises equivalent plastic strain
distribution in the disk forgings after the spinning is stopped; and FIG. 4f shows a slight plastic deformation of 0.05%-0.25% introduced into an actual part region of the disk forgings by the pre-spinning;
[00022] FIG. 5a to FIG. 5d show the variation of dimensions of a feature member of a disk
forgings during pre-spinning according to a method of the present application, in which: FIG.
a shows the relationship between the change in dimension of the disk forgings and the
maximum spinning speed of the pre-spinning when there is no initial heat treatment stress
(Ginitial=0); FIG. 5b shows the effect of heat treatment stress on the change in the outer
diameter of the disk forgings, in which the greater the initial stress is, the lower the critical
spinning speed required for yielding is; FIG. 5c shows the change in the dimension of the
disk forgings during spinning under different initial stresses; and FIG. 5d shows that heat
treatment stress has already started to have a significant effect on the variation of the outer
diameter dimension of the disk forgings during increasing the spinning speed;
[00023] FIG. 6 shows a stress release curve during pre-spinning according to Example 1 of
the present application;
[00024] FIG. 7 shows an internal stress result obtained by simulating pre-spinning by a
predicted revolution before and after pre-spinning according to Example 1 of the present
application;
[00025] FIG. 8a and FIG. 8b show a change in mechanical properties before and after
pre-spinning according to Example 1 of the present application;
[00026] FIG. 9a to FIG. 9d show a regulation effect of the pre-spinning treatment on the
stress state of a high scroll according to Example 2 of the present application; and
[00027] FIG. 10a and FIG. 10b show a stress release curve during pre-spinning and a internal
stress result obtained by simulating pre-spinning by a predicted revolution before and after
pre-spinning according to Example 2 of the present application, and FIG. 10c shows the
dimensional change in Example 2 during an overspeed spinning test.
Detailed Description
[00028] Specific implementation modes of the present application will be described in detail below with reference to the accompanying drawings. It is to be understood that the specific implementation modes described herein is illustrative and explanatory of the present application only and is not restrictive of the present application.
[00029] In the present application, orientation wordings such as "upper, lower, left, right"
are generally used to refer to upper, lower, left, and right as shown with reference to the
drawings, if they are not described to the contrary; by "inner, outer" is meant the inner and
outer relative to the contours of the members themselves. Hereinafter, the present
application will be described in detail with reference to the accompanying drawings and
implementation modes.
[00030] The present application provides a method for internal stress regulation in
superalloy disk forgings by pre-spinning. The method Includes:
[00031] Step S1, determining a target revolution for regulating an internal stress in the disk
forgings, and determining a target deformation magnitude of plastic deformation required
for regulating the internal stress by the pre-spinning of the disk forgings; and
[00032] Step S2, performing the pre-spinning of the disk forgings by the target revolution,
monitoring the deformation magnitude of the disk forgings, and stopping the pre-spinning
when the deformation magnitude of the disk forgings reached the target deformation
magnitude.
[00033] According to the method disclosed by the present application, the internal stress in
the disk forgings can be effectively regulated, while the mechanical property of the disk
forgings is maintained. Therefore, the deformation degree of subsequent part machining can
be alleviated so as to shorten the part machining period and reduce the cost. There is no
harmful deformation occurred in subsequent overspeed test and the service life of the
machined part, and thus the dimensional stability of the part is guaranteed. By forming
internal stress distribution beneficial to the working condition of the disk forgings after
pre-spinning, compressive stress is planted into the hub, and the fatigue life of the disk
forgings can be effectively prolonged.
[00034] Specifically, according to the method provided by the present application, pre-spinning can be performed at a high-speed spinning platform so that the whole disk forgings are subjected to yielding, resulting in micro plastic deformation, thereby regulating the internal stress in the disk forgings.
In addition, by regulating the internal stress in the disk forgings, the possibility of part
warping and deformation during subsequent machining is avoided, facilitating the
improvement of the machining efficiency and dimension precision.
[00035] In addition, because the disk forgings without obvious stress concentration is
adopted for pre-spinning, in order to achieve yielding of the whole disk, the internal stress is
regulated under a revolution of the pre-spinning much higher than the revolution in service.
Therefore, in subsequent overspeed strength test, it can be ensured that no harmful
deformation exceeding design requirements occurs under 115% or 120% high-stress state.
Likewise, harmful deformation will not occur in service so that the dimension control of the
parts is facilitated.
[00036] Moreover, by stopping the pre-spinning, the spinning speed of the disk forgings is
decreased, so that a stress distribution of internal pressure and external tension is formed
along the radial direction of the disk forgings, which is favorable for working conditions
during service (compressive stress is planted in the hub of the disk piece), thereby effectively
prolonging the fatigue life of the disk forgings.
[00037] Compared with the traditional method for decreasing the internal stress in the disk
forgings merely by controlling the cooling speed of the heat treatment, the present method
can not only solve the problem of machining deformation, but also ensure that no more
harmful deformation exceeding a designed deformation occurs in the overspeed strength
test state and in subsequent service life because the internal stress is regulated in advance.
[00038] In the present application, the target revolution for regulating the internal stress in
the disk forgings can be determined according to an appropriate manner, for example, a
simulation. According to a preferred embodiment of the present application, the target
revolution can be obtained by performing correction according to the simulation result.
Specifically, Step S1 includes: Step S11, obtaining a predicted revolution for regulating the internal stress in the disk forgings by simulated calculation; Step S12, performing the pre-spinning of the disk forgings by the predicted revolution, and monitoring the deformation magnitude of the disk forgings; and Step S13, adjusting the predicted revolution according to a monitored deformation magnitude of the disk forgings to determine the target revolution.
[00039] In other words, in the preferred implementation of the present application, the
predicted revolution is firstly determined in Step S11, then pre-spinning is performed by the
predicted revolution in Step S12, and finally, the revolution is adjusted in Step S13 according
to the deformation magnitude of the disk forgings to correct the predicted revolution and
obtain the target revolution. After the target revolution is determined by the disk forgings, a
disk forgings having the same specification and state as those of the disk forgings can be
pre-spun by the determined target revolution.
[00040] In Step S11, in order to obtain the predicted revolution, the internal stress in the
disk forgings can be obtained by simulated calculation, and the target internal stress to be
regulated can be set as required. In particular, when regulating the internal stress, it is
necessary to control the deformation magnitude of micro plastic deformation in order to
maintain the mechanical properties of disk forgings. To this end, Step S11 may include: Step
S111, simulating heat treatment of the disk forgings to obtain an internal stress distribution
of the disk forgings; and Step S112, simulating the pre-spinning of the disk forgings by
different revolutions to determine the predicted revolution; in which the pre-spinning by the
predicted revolution enables the internal stress in the disk forgings to be regulated to be
400MPa or below and enables the deformation magnitude of the disk forgings to be
0.05%-1.95%.
[00041] In particular, in order to obtain a more precise internal stress distribution of the disk
forgings, the simulation result can be corrected by the actually detected internal stress
distribution of the disk forgings. Specifically, Step S111may include: obtaining the internal
stress distribution by detecting an actual internal stress in the disk forgings, and correcting a
simulation result of the disk forgings by using the actual internal stress.
[00042] Those skilled in the art will appreciate that the heat treatment and pre-spinning of
the disk forgings can be simulated in a variety of appropriate manners. For example, the
material, dimension, and heat treatment process of the disk forgings can be set, and finite
element simulation (e.g., using ansys software) can be performed to simulate the heat
treatment of the disk forgings. For example, the heat treatment can be simulated with
reference to "Progresses in Research of Numerical Simulation of Heat treatment on Steel"
(Journal of Tianjin University of Technology and Education, Vol. 24, No. 3, September 2014).
Correspondingly, the pre-spinning of the disk forgings can be simulated by increasing
spinning movements according to parameters such as the revolution of the pre-spinning and
the like.
[00043] Under a condition not taking initial heat treatment stress (oinitia=O) into
consideration, in the whole process of simulating the pre-spinning treatment and after
stopping the spinning when the treatment is completed, the stress-strain values at individual
positions on the disk forgings are generally a function of the diameter of the disk forgings,
independent of the specific geometric dimension feature of the cross section of the disk
forgings, as shown in FIGs. 3A-3d. When the pre-spinning reaches a maximum spinning
speed, as shown in FIG. 3a, the yield point has been reached in the region between the inner
diameter Dinner and the contour line numbered A (the yield strength of the material at room
temperature is set to 1150MPa). In the process of increasing the revolution, the plastic
deformation firstly starts from the inner diameter Dinner of the disk forgings and gradually
expands outwards radially. Accordingly, by precisely controlling the maximum spinning
speed of the pre-spinning, the range in which the yield point is reached on the disk forgings
can be precisely controlled, and the specific plastic deformation magnitude can be acquired.
As can be seen from FIGs. 3c and 3d, for a low scroll with (Douter-Dinner)/Dinner<<1, the plastic
deformation magnitude of the disk forgings from the inner diameter Dinner to the outer
diameter Douter, i.e. an overall plastic deformation magnitude of the disk forgings, can be
controlled within a small range of 0.05%-0.25%.
[00044] FIGs. 4a to 4f show the results of pre-spinning simulation in the presence of heat
treatment stress (i.e. an actual state of the disk forgings). By comparison, it can be seen that, in the presence of heat treatment internal stress, the stress distribution and deformation behavior of the disk forgings during pre-spinning are greatly different from those in an ideal state without initial stress given in FIGs. 3a to 3d. The reason lies in that, due to the presence of the internal stress of the initial heat treatment, the initial chordwise tensile stress is superimposed with a pre-spinning centrifugal force at a position where the tensile stress is formed inside the disk forgings, so that the critical pre-spinning speed required for the corresponding region to reach the yield point is much lower than that for a situation where there is no initial stress, as shown in FIG. 5b. The greater the initial chordwise tensile stress introduced by heat treatment is, the lower the critical spinning speed required by the disk forgings for reaching the yield point during the pre-spinning is. In addition, a position on the disk forgings which reaches the yield point at the earliest time is no longer at the inner diameter Dinner, but at the position with an initial maximum tensile stress formed in the inner region of the cross section due to heat treatment. As the spinning speed increases, the range in which the yield point is reached gradually expands from the position with maximum tensile stress to adjacent regions. Under a constant maximum spinning speed, with the increase of the heat treatment internal stress, the change in the outer diameter of the disk forgings after spinning treatment is increased. The reason lies in that, the more the heat treatment stress as regulated as a whole is, the more the elastic deformation magnitude of individual positions in the disk forgings recovered due to the loss of stress constraint is.
Specifically, along with the heat treatment stress of the disk forgings, the tensile stress in the
tensile stress region is regulated by generating local plastic deformation, and the
compressive stress region which is in a balanced state with the tensile stress region due to
mutual constraint can be synchronously and elastically stretched due to the loss of the
constraint, macroscopic manifestation of which is that, the higher the internal stress of the
heat treatment is, the larger a permanent increase in the value of the outer diameter Douter
of the disk forgings after pre-spinning treatment is. FIG. 5c shows the dynamic variation of
the outer diameter Douter of the disk forgings vs. the spinning speed during the whole
process of loading and unloading in pre-spinning by a maximum spinning speed of 9750
rotations permin. For one specific pre-spinning, the disk forgings is directly proportional to
the square of the spinning speed in the elastic deformation stage. Comparing FIG. 5c with
FIG. 5d, it can be seen that the increasing speed of the outer diameter of the disk forgings is
accelerated after the yielding starts, however, in the unloading stage after reaching the
maximum spinning speed, the outer diameter of the disk forgings remains a linear
relationship with the square of the spinning speed. With the increase of the heat treatment
internal stress, under the same pre-spinning condition, the initial yielding time of disk
forgings becomes earlier, and the permanent deformation magnitude of the outer diameter
after unloading becomes larger. In particular, FIG. 5d, which is a partially enlarged view of
the spinning speed increasing stage in FIG. 5c, shows that the magnitude of the heat
treatment internal stress has a significant influence on the deformation behavior of the disk
forgings at the early stage of the spinning speed increase.
[00045] When the disk forgings is of the low scroll structure as shown in FIG. 1b, in which
the disk forgings has a dimension feature that the diameter Dinner of an inner hole is close to
the diameter Douter of an outer circle and both of them are relatively large, namely
(Douter-Dinner)/Dinner<<1, individual gradients of the stress-strain amounts formed on the cross
section of the disk forgings by the pre-spinning are relatively small, and the overall
distribution is relatively even. Such a feature of a low scroll configuration makes it possible
to realize complete yielding of the disk forgings and acquire a trace amount of permanent
plastic deformation by the technology of pre-spinning the disk forgings, by which the
internal stress distribution state of "internal pressure and external tension" caused by heat
treatment can be completely reconstructed. In fact, all the configurations of turning pieces
with annular features like the low scroll are suitable for regulating the stress distribution
state of the disk forgings by adopting a pre-spinning method.
[00046] Compared with parts such as a low scroll, a labyrinth disk, and a baffle or the like
having small cross sections, when the disk forgings is of the high scroll structure as shown in
FIG. la, a higher level of internal stress is often formed in the disk forgings during heat
treatment due to features of usually heavy weight of the high scroll and large thickness at a
site such as a hub or the like. The overall structural features of the high scroll part are that
the outer contour is relatively thick and large and the structure has high rigidity, therefore,
the problem of affecting the dimension of the parts by the heat treatment internal stress in the machining process is often not as serious as that in other thin-wall disk pieces.
[00047] However, during the procedure of over-spinning test and service on a machine, if
the tensile stress in the heat treatment internal stress is superimposed with a service load, it
is possible for a specific position of the disk forgings to reach the yield point within the
spinning speed range much lower than the nominal load. In the working process of the disk
forgings, once a local yielding phenomenon occurs in the residual tension region, the overall
regulation of the internal stress of the heat treatment will be resulted in, which is
manifested as harmful deformation in macroscopic dimension of the disk forgings beyond
expectation. In fact, excessive heat treatment internal stress is one of the leading reasons for
the loss of dimensional stability for a high scroll in service under a working condition with a
strength much lower than a designed strength.
[00048] The difference between the inner diameter and the outer diameter of the high
scroll is large, namely (Douter-Dinner)/Dinner>>1. Therefore, if a spinning speed for yielding the
whole of the high scroll is adopted for pretreatment, the plastic deformation magnitude at
the inner diameter position will be too large, negatively influencing the structural
performance of the material.
[00049] However, due to the high heat treatment tensile stress present in a specific region
of the hub position of the high scroll, a maximum tensile stress position on the disk forgings
reaches the yield point in a low spinning speed range, even at a spinning speed lower than
that required for the yielding at the inner hole Dinner, so that the heat treatment internal
stress is effectively regulated.
[00050] As can be seen from FIGs. 9a and 9b, the heat-treated high scroll has very high
internal stress, the maximum tensile stress therein appears in the inner region of the hub,
the maximum tensile stress reaches up to 700-900MPa, and accordingly, the maximum
compressive stress on the surface of the disk forgings can reach 100OMPa or higher. If the
yield strength of the material is 1200MPa at room temperature, the hub position will
actually enter a yielding state when the working load at the hub position in service reaches
500MPa or higher, so that the internal stress on the disk forgings is regulated. At this time, a harmful deformation beyond expectation will be generated in the disk forgings under a working condition with a yield strength much lower than the nominal yield strength.
[00051] Different from a pre-spinning of a low stroll which can achieve a yielding for the
whole disk forgings, for the purpose of preventing excessive plastic deformation magnitude,
a plastic deformation will be usually introduced to the high scroll only at the hub position at
the highest pre-spinning speed so as to ensure that the tensile stress of the hub region is
sufficiently regulated. The web and the rim region will not be subjected to plastic
deformation at all during pre-spinning, therefore, the microstructure states such as
dislocation density and the like at the rim position will be not influenced. As such, it is
ensured that the yield strength and the fatigue performance of the hub position are
improved, and the high-temperature creep endurance performance of the rim position is
not attenuated.
[00052] By implementing the pre-spinning, as shown in FIGs. 9c and 9d, the chordwise
tensile stress region in the inner region of the hub is substantially eliminated, the heat
treatment internal stress in the disk forgings is effectively regulated, and meanwhile, the
compressive stress which is distributed in gradients from the inner hole along the diameter
direction covers a region corresponding to the web of the disk forgings. The internal stress
distribution state adjusted by the pre-spinning, particularly the chordwise compressive
stress implanted in the hub region, can significantly improve the fatigue performance of the
disk forgings. More importantly, due to the elimination of excessive chordwise tensile stress
in the hub, the disk forgings can be prevented from reaching the yield point too early in
subsequent service due to the residual tension superposed with a working stress, which
otherwise would lead to harmful deformation of the disk forgings due to internal stress
regulation. Therefore, the pre-spinning treatment of the disk forgings is an effective stress
regulation means, and has very important engineering application value for ensuring
dimensional stability of a high scroll in subsequent service life.
[00053] In addition, in Step S112, in order to properly set the predicted revolution, the
required degree of regulation can be set according to the internal stress distribution
obtained by simulation, that is, the internal stress of the pre-spun disk forgings is regulated to be 400MPa or below. Specifically, different pre-spinning revolutions can be set for simulating the pre-spinning, and a finally determined predicted revolution shall be the one enabling the internal stress of the pre-spun disk forgings to be regulated to be 400MPa or below. In particular, the predicted revolution determined by the simulated pre-spinning further entails a deformation magnitude of the disk forgings of 0.05%-1.95%, so that the disk forgings is prevented from generating excessive plastic deformation and influencing the mechanical properties of the disk forgings.
[00054] In the above Step S13, the revolution of the pre-spinning can be adjusted adaptively
according to comparison result between the monitored deformation magnitude of the disk
forgings and the target deformation magnitude. Specifically, Step S13 includes: S131
determining the predicted revolution as the target revolution if the monitored deformation
magnitude of the disk forgings reaches the target deformation magnitude when performing
the pre-spinning of the disk forgings by the predicted revolution; or Step S132, if the
monitored deformation magnitude of the disk forgings is lower than the target deformation
magnitude when performing the pre-spinning of the disk forgings by the predicted
revolution, gradually increasing the revolution of the pre-spinning until the monitored
deformation magnitude of the disk forgings reaches the target deformation magnitude when
performing the pre-spinning by a final revolution, and determining the final revolution as the
target revolution.
[00055] Step S131is applicable to a case where the predicted revolution is relatively precise,
i.e., a required target deformation magnitude can be reached by pre-spinning by the
predicted revolution. Step S132 is applicable to a case where the predicted revolution is not
precise enough (i.e., pre-spun by the predicted revolution can not reach the target
deformation magnitude) and the modification is required, in which a specific modification is
to gradually increase the revolution of the pre-spinning. In order to precisely determine the
target revolution, it is possible to properly set the revolutions increased each time.
Preferably, Step S132 includes: gradually increasing the revolution of the pre-spinning by a
step of 25-100 rotations per minute if the monitored deformation magnitude of the disk
forgings is lower than the target deformation magnitude when performing the pre-spinning of the disk forgings by the predicted revolution.
[00056] In addition, in order to avoid the influence of excessive plastic deformation of the
disk forgings caused by pre-spinning on mechanical properties, the target deformation
magnitude can be properly set such that only slight plastic deformation of the disk forgings
occurs, and preferably, the target deformation magnitude is 0.05%-1.95%. When monitoring
the deformation magnitude of the disk forgings, the deformation magnitude of a specific
position (for example, at the outer diameter) on the disk forgings is often monitored.
However, the deformation magnitudes varies at different positions on the overall disk
forgings. For example, the deformation magnitude at the inner diameter is larger than that
at the outer diameter. Therefore, the range of the deformation magnitude at individual
positions shall be guaranteed to be within the range of the target deformation magnitude.
[00057] Further, in order to precisely monitor the deformation magnitude of the disk
forgings, it is preferable to monitor the deformation magnitude of the disk forgings after
keeping the current revolution of the pre-spinning for at least 30 seconds so as to ensure
that the monitoring is performed while the plastic deformation generated by the
pre-spinning has been stabilized.
[00058] In addition, during the plastic deformation of the disk forgings due to pre-spinning,
the disk forgings is subject to a change from elastic deformation to plastic deformation,
therefore, the deformation magnitude of the disk forgings will be continuously changed until
reaching a stable value. In order to precisely monitor the deformation magnitude, preferably,
when monitoring the deformation magnitude of the disk forgings, a stable value is taken as
the monitored deformation magnitude of the disk forgings. In particular, when the
monitored deformation magnitude fluctuates in the range of ±0.01mm within 15s, it could
be considered that a stable value is reached.
[00059] According to the method of the present application, in order to finally form a stress
distribution state of internal pressure and external tension beneficial to a working condition
during service along the radial direction of the disk forgings, Step S2 includes: gradually
decreasing the revolution of the pre-spinning to zero when it is monitored that the deformation magnitude of the disk forgings reaches the target deformation magnitude.
Specifically, the revolution may be gradually decreased by 1-200 rotations per second until
the pre-spinning stops.
[00060] The method of the present application is applicable to various superalloy disk
forgings with high internal stress. In particular, the superalloy includes a wrought superalloy,
a powder superalloy, or a cast superalloy.
[00061] In addition, in order to verify the effect of the method provided by the present
application, step S3 is included: drawing a internal stress distribution diagram of the disk
forgings after pre-spinning. By drawing a internal stress distribution diagram after
pre-spinning, the technical effect of the present application can be more visually seen. In
particular, the internal stress distribution diagram after pre-spinning can be drawn in a
variety of suitable manners, for example drawing by simulation. To improve the efficiency,
preferably, step S3 includes: S31, simulating the pre-spinning of the disk forgings by the
target revolution to obtain the internal stress distribution of the disk forgings after the
pre-spinning; and S32, detecting the actual internal stress at a feature site of the disk
forgings (for example, a position with small fluctuation of the stress distribution selected
according to a simulated result), and correcting the simulated result of the disk forgings after
pre-spinning by using the actual internal stress so as to obtain the internal stress distribution
of the disk forgings after pre-spinning.
[00062] In the present application, the actual internal stress of the feature position of the
disk forgings can be detected in an appropriate manner. For example, 0.2mm or more below
the surface of the feature site of the disk forgings can be measured by an X-ray diffraction
method.
[00063] In order to ensure the final effect, the disk forgings applicable to the present
application is a disk structure without obvious stress concentration before pre-spinning,
including, but not being limited to, annular disk forgings, compressor disk forgings, turbine
disk forgings and the like. Further, the pre-spinning operating temperature suitable for the
present application is -50°C-750 °C, in particular, room temperature. Particular operating temperature depends primarily on the ratio of the tensile strength of the material to the yield strength of the material.
[00064] In the present application, various suitable high-speed spinning equipment can be
adopted for pre-spinning as long as the conditions of spinning speed control, temperature,
and the like required by pre-spinning the disk forgings can be met. The deformation
magnitude in the pre-spinning process can be monitored by using suitable equipment, for
example, by infrared displacement detection.
[00065] The method of the present application will be illustrated by the following Examples.
Example 1:
[00066] An annular low-pressure turbine disk forgings of GH4065 alloy was used, and the
structure thereof was as shown in FIG. 1b. The inner diameter was 0618mm, the outer
diameter was ©829mm, the height was 85mm, and the weight was 130kg. After standard
heat treatment, the chordwise internal stress in the disk forgings was the main stress. The
X-ray diffraction method was adopted to detect 0.2 mm or more below the feature site. The
chordwise internal stress at the hub was -384MPa, the chordwise internal stress at the web
was -641MPa, and the chordwise internal stress at the rim was -740MPa, showing a
high-stress level.
[00067] The internal stress distribution of the disk forgings was obtained by simulating the
heat treatment of the disk forgings, and as shown in FIG. 2c, the simulated result was
consistent with the detection result.
[00068] The pre-spinning was then simulated. For a low scroll with (Duter-Dinner)/Dinner<<1,
the plastic deformation magnitude of the disk forgings from the inner diameter Dinner to the
outer diameter Douter, i.e. the overall plastic deformation magnitude of the disk forgings, was
controlled within a small range of 0.05%-0.25%.
[00069] As shown in FIGs. 4a to 4f, the stress-strain distribution of the disk forgings during
the pre-spinning by different revolutions in the presence of heat treatment stress was
simulated, the maximum chordwise tensile stress in the disk forgings was regulated to be
400MPa or below, and the predicted revolution corresponding to an overall deformation of
0.15%-0.25% is 9400 rotations per minute.
[00070] The pre-spinning was performed on the disk forgings at 9400 rotations per minute
for 60 seconds. As shown in FIG. 6, the deformation magnitude of the disk forgings was
monitored, the residual deformation at the outer diameter was detected to be 0.75mm, and
the overall deformation magnitude corresponding to the disk forgings is 0.18-0.24%,
reaching the target deformation magnitude, therefore, the predicted revolution was
determined as the target revolution. The internal stress can be regulated by the pre-spinning
of 9400 rotations per minute for a batch of disk forgings with the same specification.
[00071] In order to verify the effect of the present application, the X-ray diffraction method
was adopted to measure internal stress (the result was shown in FIG. 7) 0.2 mm or more
below the surface of a feature site (for example, a region with small fluctuation of stress
distribution selected according to a simulated result) of the disk forgings before and after
the pre-spinning. The test result was substantially consistent with the simulated result.
Finally, the internal stress distribution diagram after the pre-spinning was drawn, ready for a
subsequent disk piece machining process.
[00072] No abnormality was found in the pre-spun disk forgings by ultrasonic inspection.
Further dissection was carried out on the disk piece, showing that the microstructure of the
disk piece and mechanical properties at various positions (results shown in FIGs. 8a and 8b)
were not significantly different from those of a disk piece without subjecting to the
pre-spinning.
Example 2:
[00073] A typical alloy turbine disk forgings of powder superalloy FGH96 (hereinafter also
referred to as a high scroll) was treated using the method of Example 1. The structure was
shown in FIG. la, with an inner diameter of ©125mm, an outer diameter of 0550mm, a hub
height of 215mm, and a rim height of 60mm. The disk forgings was subjected to standard
heat treatment. The internal stress distribution of the disk forgings was obtained by
simulating the heat treatment of the disk forgings. The result was shown in FIGs. 9a and 9b,
in which the maximum chordwise tensile stress in the disk piece reached above 700MPa, which was relatively high.
[00074] The pre-spinning of the disk forgings by different revolutions was simulated, the
maximum chordwise tensile stress in the disk forgings was reduced to 400MPa or below, and
the predicted revolution corresponding to the overall deformation of 0.15-1.0% was 23500
rotations per minute.
[00075] The test piece of the disk forgings was pre-spun at 23500 rotations per minute for
seconds. The deformation magnitude of the test piece was monitored. The residual
deformation was measured to be 0.70mm, and the corresponding deformation magnitude
was 0.12-0.88%, therefore, the target deformation magnitude cannot be reached. The
revolution was increased by 50 rotations each time. When a final revolution was 23550
rotations per minute, the residual deformation reached 0.82mm, reaching a target
deformation magnitude of 0.15-0.98%, therefore, the final revolution was determined as the
target revolution. The internal stress can be regulated by the pre-spinning of 23550 rotations
per minute for a batch of disk pieces with the same specification.
[00076] In order to verify the effect of the present application, the internal stress was
measured 0.2mm or more below the surface of a feature site of the disk forgings before and
after the pre-spinning (the result was shown in FIG. 10b). The test result was consistent with
the simulated result. By ultrasonic inspection to the pre-spun disk piece and an overall
dissection performance test to the disk forgings, no significant change was found.
[00077] In addition, in order to verify the effect of the present application in terms of
dimensional stability, an overspeed test was performed for the pre-spun piece and the
non-pre-spun piece. The test result was shown in FIG. 10c. The dimension of the pre-spun
disk piece was substantially unchanged in 122% overspeed test.
[00078] The preferred implementation modes of the present application are described in
detail above with reference to the accompanying drawings, but the present application is
not limited thereto. Many simple variations of the technical scheme of the present
application are possible within the scope of the technical idea of the present application.
The present application includes the combination of various specific technical features in any suitable manner. In order to avoid unnecessary repetition, the present application will not be further described with respect to various possible combinations. However, such simple variations and combinations should also be considered as the disclosed content of the present application, falling within the scope of the present application.
Claims (6)
1. A method for internal stress regulation in superalloy disk forgings by pre-spinning, comprising:
Step S1 determining a target revolution for regulating internal stress in the disk forgings, and determining a target deformation magnitude of plastic deformation required for
regulating the internal stress by the pre-spinning of the disk forgings;
wherein Step S1 comprises:
Step S11 obtaining a predicted revolution for regulating the internal stress in the disk forgings by simulated calculation; Step S11 comprising:
Step Sil1 obtaining internal stress distribution of the disk forgings by simulating heat treatment of the disk forgings; Step S111 comprising:
obtaining a internal stress distribution of the disk forgings after heat treatment
by detecting an actual internal stress in the disk forgings and correcting a simulated result of the disk forgings by using the actual internal stress; and
Step S112 simulating the pre-spinning of the disk forgings by different revolutions to determine the predicted revolution; wherein the pre-spinning by the predicted
revolution enables the internal stress in the disk forgings to be regulated to be 400MP or below and enables residual deformation magnitude of the disk forgings
to be 0.05%-1.95%;
Step S12 performing the pre-spinning of the disk forgings by the predicted revolution, and monitoring the deformation magnitude of the disk forgings; and
Step S13 adjusting the predicted revolution according to a monitored deformation magnitude of the disk forgings to determine a target revolution; Step S13 comprising:
S131 determining the predicted revolution as the target revolution if the monitored deformation magnitude of the disk forgings reaches the target deformation
magnitude when performing the pre-spinning of the disk forgings by the predicted revolution; or
S132 if the monitored deformation magnitude of the disk forgings is lower than the target deformation magnitude when performing the pre-spinning of the disk forgings by the predicted revolution, gradually increasing the revolution of the pre spinning until the monitored deformation magnitude of the disk forgings reaches the target deformation magnitude when performing a final revolution of pre spinning, and determining the final revolution as the target revolution; Step S132 comprising: gradually increasing the revolution of the pre-spinning by a step of 25-100 rotations per minute if the monitored deformation magnitude of the disk forgings is lower than the target deformation magnitude when performing the pre-spinning of the disk forgings by the predicted revolution;
Step S2 performing the pre-spinning of the disk forgings by the target revolution, monitoring the deformation magnitude of the disk forgings, and stopping the pre-spinning when a
monitored deformation magnitude of the disk forgings reaches the target deformation magnitude; and
Step S3: drawing a internal stress distribution diagram of the disk forgings after pre spinning, preferably, Step S3 comprising:
Step S31 simulating the pre-spinning of the disk forgings by the target revolution to obtain the internal stress distribution of the disk forgings after the pre-spinning; and
Step S32: detecting an actual internal stress at a feature site of the disk forgings, and
correcting a simulated result of the disk forgings after pre-spinning by using the actual internal stress to obtain the internal stress distribution of the disk forgings after pre
spinning;
wherein the target deformation magnitude is 0.05% - 1.95%,
wherein the deformation magnitude of the disk forgings is monitored after keeping a current revolution for at least 30 seconds when performing the pre-spinning.
2. The method for internal stress regulation in superalloy disk forgings by pre-spinning according to claim 1, wherein:
when monitoring the deformation magnitude of the disk forgings, a stable value is taken as the monitored deformation magnitude of the disk forgings; and/or
Step S2 comprises: gradually decreasing the revolution of the pre-spinning to zero when
it is monitored that the deformation magnitude of the disk forgings reaches the target deformation magnitude.
3. The method for internal stress regulation in superalloy disk forgings by pre-spinning according to claim 1, wherein the superalloy is a wrought superalloy, a powder superalloy,
or a cast superalloy.
4. The method for internal stress regulation in superalloy disk forgings by pre-spinning
according to claim 1, wherein the disk forgings is a disk structure without obvious stress concentration before the pre-spinning, and the disk forgings comprises annular disk
forgings, compressor disk forgings and turbine disk forgings.
5. The method for internal stress regulation in superalloy disk forgings by pre-spinning according to claim 1, wherein a pre-spinning operating temperature is -50°C-750C.
6. The method for internal stress regulation in superalloy disk forgings by pre-spinning according to claim 1, wherein the pre-spinning is performed by using a high-speed spinning
test platform and a matched tool for positioning the disk forgings on the high-speed spinning test platform.
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| CN112016223A (en) * | 2020-07-20 | 2020-12-01 | 浙江海骆航空科技有限公司 | Test device and method for eliminating residual stress by pre-rotating turbine blank disc |
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| CN109145335A (en) * | 2017-06-28 | 2019-01-04 | 中国航发贵阳发动机设计研究所 | A method of wheel disc low cycle fatigue life is improved by pre-rotation |
| CN110423883A (en) * | 2019-08-08 | 2019-11-08 | 北京航空航天大学 | A kind of large ring rotating centrifugal residual stress regulation method |
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