EP2312000A1 - Procédé de forgeage d'un superalliage à base de nickel - Google Patents

Procédé de forgeage d'un superalliage à base de nickel Download PDF

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Publication number
EP2312000A1
EP2312000A1 EP10176784A EP10176784A EP2312000A1 EP 2312000 A1 EP2312000 A1 EP 2312000A1 EP 10176784 A EP10176784 A EP 10176784A EP 10176784 A EP10176784 A EP 10176784A EP 2312000 A1 EP2312000 A1 EP 2312000A1
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EP
European Patent Office
Prior art keywords
nickel base
base superalloy
forging
forged component
preform
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP10176784A
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German (de)
English (en)
Inventor
Robert Mitchell
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce PLC
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Rolls Royce PLC
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Filing date
Publication date
Application filed by Rolls Royce PLC filed Critical Rolls Royce PLC
Publication of EP2312000A1 publication Critical patent/EP2312000A1/fr
Withdrawn legal-status Critical Current

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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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/056—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%

Definitions

  • the present invention relates to a method of forging a nickel base superalloy and in particular to a method of forging a nickel base superalloy turbine disc or a nickel base superalloy compressor disc.
  • a single component may be processed to produce a range of grain sizes, with different grain sizes at different locations, e.g. a dual microstructure turbine disc.
  • the grain size achieved in these nickel base superalloys is influenced by three factors.
  • the first factor is alloy chemistry, in particular the levels of boron and carbon.
  • the levels of boron and carbon dictate the levels of borides or carbides present in the nickel base superalloy and these borides or carbides pin grain boundaries and restrict grain growth.
  • the second factor is processing parameters, principally forging temperature, strain rate and final strain.
  • the third factor is heat treatment. Fine grain nickel base superalloys are heat treated below the gamma-prime solvus temperature, a subsolvus heat treatment, the gamma-prime phase acts to pin the grain boundaries.
  • Coarse grain nickel superalloys are heat treated above the gamma-prime solvus temperature, a supersolvus heat treatment.
  • Midi grain nickel base superalloys are forged at a lower than usual temperature and then heat treated above the gamma-prime solvus temperature, supersolvus heat treatment.
  • any heat treatment that involves going above the gamma-prime solvus temperature it is necessary to have an understanding of both the chemistry of the nickel base superalloy and prior mechanical working history to avoid critical grain growth.
  • the present invention seeks to provide a novel method of forging a nickel base superalloy which has been produced by powder metallurgy, which reduces, preferably overcomes, the above mentioned problem.
  • the present invention provides a method of forging a nickel base superalloy comprising the steps of:-
  • step (b) the effective strain at the end of forging is less than or equal to 0.75.
  • step (b) the effective strain at the end of forging is less than or equal to 0.5.
  • step (a) comprises providing a stepped cylindrical preform, the cylindrical preform having a first substantially cylindrical portion and a second substantially annular portion arranged coaxially around the first portion, the first cylindrical portion having a first thickness, the second annular portion having a second thickness and the second thickness is less than the first thickness and step (b) comprises forging the stepped cylindrical preform to a substantially disc shaped forged component and after step (c) the second portion having coarser grains than the first portion.
  • step (a) comprises providing a substantially cylindrical preform, the cylindrical preform having a third substantially annular portion arranged coaxially around the second annular portion, the third annular portion having a third thickness and the third thickness is less than the second thickness and after step (c) the third portion having coarser grains than the second portion.
  • the effective strain is about 0.9, in the second annular portion the effective strain is about 0.75 and in the third annular portion the effective strain is about 0.5.
  • Step (c) may comprise a subsolvus heat treatment in a first region of the forged component and a supersolvus heat treatment in a second region of the forged component.
  • the first region may comprise the first portion and the second region may comprise the second portion or the second region comprises the second portion and the third portion.
  • Step (c) comprise supersolvus heat treating all of the nickel base superalloy forged component to produce a large grain size in all of the nickel base superalloy forged component.
  • the forged component may comprise a forged component for a turbine disc or a compressor disc.
  • a turbofan gas turbine engine 10 as shown in figure 1 , comprises in axial flow series an intake 12, a fan section 14, a compressor section 16, a combustion section 18, a turbine section 20 and an exhaust 22.
  • the turbine section 20 comprises a turbine disc 24, which carries a plurality of circumferentially space turbine blades 26.
  • the gas turbine engine 10 is quite conventional and its construction and operation will not be described further.
  • the gas turbine engine turbine disc 24 as shown more clearly in figure 2 , comprises a hub, or cob, 28, a web 30 and a rim 32.
  • the hub 28 is at the radially inner end of the turbine disc 24, the rim 32 is at the radially outer end of the turbine disc 24 and the web 30 extends radially between and interconnects the hub 28 and the rim 32.
  • the rim 32 in this example, has a plurality of circumferentially spaced slots 34 to receive the roots of turbine blades 26, shown in figure 1 , and circumferentially spaced posts 36 are provided on the rim 32 of the turbine disc 24 to define the sides of the slots 34.
  • the slots 34 may be firtree shape, or dovetail shape.
  • the turbine disc 24 comprises a high strength nickel base superalloy, for example RR1000.
  • FIGS 3 and 4 show micrographs of high strength nickel base superalloy RR1000 processed by a powder metallurgy route.
  • RR1000 consists of 18.5wt% cobalt, 15wt% chromium, 5wt% molybdenum, 2wt% tantalum, 3.6wt% titanium, 3wt% aluminium, 0.5wt% hafnium, 0.015wt% boron, 0.06wt% zirconium, 0.027wt% carbon and the balance nickel plus incidental impurities. It is to be noted that RR1000 consists of less than 0.03wt% carbon and it is preferred that the nickel base superalloy consists of less than 0.03wt% carbon.
  • Figure 4 shows RR1000 with a large grain size of ASTM 5-2 ALA 00 produced according to the present invention whereas Figure 3 shows RR1000 with a coarse grain size of ASTM 5-7 ALA 2 produced according to the prior art.
  • a nickel base superalloy turbine disc is produced by isothermal forging a substantially cylindrical preform to a substantially disc shaped forged component using a large amount of plastic deformation.
  • the effective strain at the end of the forging process is greater than 1.
  • the nickel base superalloy forged component is given a supersolvus heat treatment to produce a coarse grain size in the nickel base superalloy forged component limited to the ASTM 5-7 range of conventional coarse grain nickel base superalloys.
  • the nickel base superalloy preform is provided with a first predetermined shape, the nickel base superalloy preform having been produced by powder metallurgy, the nickel base superalloy preform is forged to produce a nickel base superalloy forged component with a second predetermined shape, wherein the first predetermined shape and the second predetermined shape are arranged such that the effective strain at the end of the forging process is less than 1.
  • the nickel base superalloy forged component is given a supersolvus heat treatment to produce a large grain size in the nickel base superalloy forged component in the ASTM 5-2 ALA 00, 80 to 140 micrometers, which is greater in size than the conventional coarse grain in nickel base superalloys.
  • Figure 5 is a graph of grain size after heat treatment against effective strain at the end of the forging process, or forging step. It is seen in figure 5 that at effective strains above 1 the grain size remains substantially constant. At effective strains below 1 the grain size increases gradually from an effective strain of 1 down to an effective strain of 0.75. The grain size increases more rapidly from an effective strain of 0.75 to an effective strain of 0.5 and then increases to a maximum grain size below an effective strain of 0.5. We have found that for an effective strain less than 1 the grain size is greater than that for an effective strain greater than 1 for identical supersolvus heat treatments. We have found that the grain size is relatively insensitive to instantaneous strain rate in RR1000 compared to the prior art.
  • Figure 6 is a graph of grain size against time above the gamma prime solvus for three series of tests, M, P and D>1 where the effective strain was greater than 1 and a single series of tests D ⁇ 1 where the effective strain was less than 1.
  • This graph shows the effect of time above the gamma prime solvus on the grain size. It is clear from the data from these tests that the grain size reaches a steady state after a short period of time. Irrespective of effective strain, grain growth does not occur immediately, but rather takes some time to occur. Grain growth occurs rapidly in the nickel base superalloy where effective strain is less than 1 before stabilising at the large grain size. Grain growth occurs more slowly in the nickel base superalloy where effective strain is greater than 1 before stabilising at the coarse grain size.
  • FIG 7 shows an example of nickel base superalloy preform 40, pre-forge, which is used in a method according to the present invention.
  • the nickel base superalloy preform 40 is a stepped cylindrical preform and the stepped cylindrical preform 40 has a first substantially cylindrical portion 42, a second substantially annular portion arranged 44 coaxially around the first cylindrical portion 42 and a third substantially annular portion 46 arranged coaxially around the second annular portion 44.
  • the first, second and third portions 42, 44 and 46 are integral.
  • the first cylindrical portion 42 has a first thickness 10h
  • the second annular portion 44 has a second thickness 4h
  • the third annular portion has a third thickness 2h.
  • the second thickness 4h is less than the first thickness 10h and the third thickness 2h is less than the second thickness 4h.
  • the second annular portion 44 is twice as thick as the third annular portion 46 and the first cylindrical portion 42 is five times thicker than the third annular portion 46.
  • Figure 8 shows a nickel base superalloy disc shaped forged component 50 which has a thickness of h, which is produced by forging, isothermally forging, the nickel base superalloy preform 40.
  • the nickel base superalloy disc shaped forged component 50 is then given a supersolvus heat treatment, such that the second annular portion 44 has coarser grains than the first portion 42 and the third portion 46 has coarser grains than the second portion 44.
  • the forging temperature is in the range of 1050°C to 1150°C, preferably in the range of 1090°C to 1120°C, and the strain rate is in the range of 0.001 to 0.1 per second, preferably 0.1 per second.
  • the disc shaped forging is produced in a close die shaped to form the nickel base superalloy preform 40 to the desired shape of the nickel base superalloy disc shaped forged component 50.
  • an effective strain E eff of less than or equal to 0.5 in order to produce a uniform large grain size in the nickel base superalloy.
  • An effective ⁇ eff of less than, or equal, to 0.75 but greater than 0.5 would produce a slightly finer grain size than the large grain size in the nickel base superalloy.
  • Figure 9 is a graph showing the grain size against position in the forged component of figure 8 following a conventional supersolvus heat treatment. It is seen that in the third annular portion 46 the grain size is larger than the second annular portion 44 and the grain size in the second annular portion 44 is larger than the grain size in the first cylindrical portion 42.
  • the nickel base superalloy preform of figure 8 is forged to produce a nickel base superalloy disc shaped forged component 50 and the nickel base superalloy disc shaped forged component 50 is given a supersolvus heat treatment and ageing heat treatment and then machined to produce a nickel base superalloy turbine disc or compressor disc.
  • the finished nickel base superalloy turbine disc will have an increasing grain size in the turbine disc with a coarse grain size in the rim 32, third annular portion 46, a finer grain size in the web 30, second annular portion 44, and a finest grain size in the hub 28, first cylindrical portion 42.
  • the nickel base superalloy preform is isothermally forged at a temperature of 1050°C to 1150°C, preferably in the range of 1090°C to 1120°C, at a strain rate in the range of 0.001 to 0.1 per second, preferably 0.1 per second.
  • the RR1000 nickel base superalloy disc shaped forging is given a conventional subsolvus solution heat treatment at 20°C to 30°C below the gamma prime solvus temperature for 1 to 4 hours, then air cooled, followed by a supersolvus heat treatment at 20°C to 50°C above the gamma prime solvus temperature for up to 1 hour, then air cooled, followed by an ageing heat treatment at 760°C (1400°F) for 16 hours and air cooled.
  • Figure 10 is a graph showing the grain size against position in the forged component of figure 8 following a dual microstructure heat treatment.
  • a dual microstructure heat treatment one region is given a supersolvus heat treatment and one region is given a subsolvus heat treatment.
  • the grain size in the third annular portion 46 is larger than the second annular portion 44 and the grain size in the second annular portion 44 is larger than the grain size in the first cylindrical portion 42.
  • the nickel base superalloy preform of figure 8 is forged to produce a nickel base superalloy disc shaped forged component 50 and the nickel base superalloy disc shaped forged component 50 is given a supersolvus heat treatment and ageing heat treatment and then machined to produce a nickel base superalloy turbine disc or compressor disc.
  • the finished nickel base superalloy turbine disc will have an increasing grain size in the turbine disc with a large grain size in the rim 32, a coarse grain size in the web 30 and a fine grain size in the hub 28.
  • the first cylindrical portion 42 is given a subsolvus heat treatment to retain fine grains in the hub 28, the second annular portion 44 and the third annular portion 46 are given a supersolvus heat treatment to produce coarse grains in the web 30 and large grains in the rim 32 respectively.
  • the first cylindrical portion is given a conventional subsolvus solution heat treatment at 20°C to 30°C below the gamma prime solvus temperature for 1 to 4 hours, then air cooled, followed by subsolvus solution heat treatment at 20°C to 30°C below the gamma prime solvus temperature for times up to 1 hour, then air cooled, followed by an ageing heat treatment at 760°C (1400°F) for 16 hours and then air cooled.
  • the second and third annular portions were given a conventional subsolvus solution heat treatment at 20°C to 30°C below the gamma prime solvus temperature for 1 to 4 hours, then air cooled, followed by a supersolvus heat treatment at 20°C to 50°C above the gamma prime solvus temperature for times up to 1 hour, then air cooled, followed by an ageing heat treatment at 760°C (1400°F) for 16 hours and air cooled.
  • a stepped cylindrical preform may be provided, the cylindrical preform has a first substantially cylindrical portion and a second substantially annular portion arranged coaxially around the first portion, the first cylindrical portion has a first thickness, the second annular portion has a second thickness and the second thickness is less than the first thickness.
  • the stepped cylindrical preform is forged to a generally disc shaped forged component and then the nickel base superalloy forged component is given a supersolvus heat treatment and ageing heat treatment and then machined to produce a nickel base superalloy turbine disc or compressor disc.
  • the second portion has coarser grains than the first portion.
  • the effective strain is kept to a level below 1, such that on subsequent supersolvus heat treatment a large grain size is produced in the nickel base superalloy. It is the final effective strain and not the maximum instantaneous strain rate of the forging process, or forging step, which dictates the grain size in the nickel base superalloy.
  • the supersolvus solution heat treatment may be applied directly after the forging step or a subsolvus heat treatment may be applied after the forging step and a supersolvus heat treatment applied after the subsolvus heat treatment.
  • the forging step may comprise isothermal forging and isothermal application of strain during the isothermal forging step allows the imparted strain levels to be accurately controlled.
  • the present invention may be applied to specific locations of a component. The present invention produces a very creep resistant, fatigue crack growth resistant nickel base superalloy with a high gamma prime volume fraction.
  • the advantage of the present invention is that it enables critical rotating components to be produced with enhanced high temperature properties, in particular creep resistance and fatigue crack growth resistance. This provides an increase in the operating life of the component or enables the component to operate at higher temperatures and may decrease the weight of the component.
  • the present invention is applicable to all high strength powder processed nickel base superalloys used for gas turbine engine turbine discs, compressor discs, high-pressure compressor cones and turbine cover plates.
  • Rene 95 consists of 8.12wt% Co, 12.94wt% Cr, 3.45wt% Mo, 3.43wt% W, 3.42wt% Al, 2.44wt% Ti, 3.37wt% Nb, 0.05wt% Zr, 0.07wt% C, 0.012wt% B and the balance Ni and incidental impurities.
  • Rene 88DT consists of 13.1wt% Co, 15.8wt% Cr, 4wt% Mo, 3.9wt% W, 2wt% Al, 3.7wt% Ti, 0.7wt% Nb, 0.045wt% Zr, 0.05wt% C, 0.016wt% B and the balance Ni and incidental impurities.
  • Alloy 10 consists of 17.93wt% Co, 10.46wt% Cr, 2.52wt% Mo, 4.74wt% W, 3.53wt% Al, 3.79wt% Ti, 1.61wt% Ta, 0.97wt% Nb, 0.07wt% Zr, 0.027wt% C, 0.028wt% B and the balance Ni and incidental impurities.
  • LSHR consists of 20.8wt% Co, 12.7wt% Cr, 2.74wt% Mo, 4.37wt% W, 3.48wt% Al, 3.47wt% Ti, 1.65wt% Ta, 0.049wt% Zr, 0.024wt% C, 0.028wt% B and the balance Ni and incidental impurities.
  • Rene 104 consists of 20.6wt% Co, 13.0wt% Cr, 3.80wt% Mo, 2.1wt% W, 3.4wt% Al, 3.7wt% Ti, 2.4wt% Ta, 0.05wt% Zr, 0.04wt% C, 0.03wt% B and the balance Ni and incidental impurities.
  • IN100 consists of 18.5wt% Co, 12.5wt% Cr, 3.2wt% Mo, 5.0wt% Al, 4.4wt% Ti, 0.06wt% Zr, 0.07wt% C, 0.02wt% B and the balance Ni and incidental impurities.
  • the subsolvus heat treatment for these nickel base superalloys is at a temperature of 20°C to 40°C below the gamma prime solvus temperature for times of 1 to 6 hours and the supersolvus heat treatment for these nickel base superalloys is at a temperature of 20°C to 50°C above the gamma prime solvus temperature for times of up to 4 hours.
  • the subsolvus heat treatment is 1110°C to 1150°C for times of 1 to 6 hours and the supersolvus heat treatment is 1160°C to 1210°C for times of up to 4 hours.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Forging (AREA)
EP10176784A 2009-10-15 2010-09-15 Procédé de forgeage d'un superalliage à base de nickel Withdrawn EP2312000A1 (fr)

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GBGB0918020.9A GB0918020D0 (en) 2009-10-15 2009-10-15 A method of forging a nickel base superalloy

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2407565A1 (fr) * 2010-07-12 2012-01-18 Rolls-Royce plc Procédé pour améliorer les propriétés mécaniques d'un composant
US20130167979A1 (en) * 2011-12-29 2013-07-04 General Electric Company Method of predicting quench cracking in components formed by high deformation processes
CN107427896A (zh) * 2015-03-25 2017-12-01 日立金属株式会社 Ni基超耐热合金的制造方法

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WO2012063879A1 (fr) * 2010-11-10 2012-05-18 本田技研工業株式会社 Alliage de nickel
US9291057B2 (en) * 2012-07-18 2016-03-22 United Technologies Corporation Tie shaft for gas turbine engine and flow forming method for manufacturing same
EP3083138A4 (fr) * 2013-12-17 2017-09-06 United Technologies Corporation Composants de turbine à gaz usinés par abrasion
CN103894599B (zh) * 2014-03-14 2016-04-13 华南理工大学 一种镍基粉末冶金修复材料及其应用
US10563293B2 (en) 2015-12-07 2020-02-18 Ati Properties Llc Methods for processing nickel-base alloys
US20180371924A1 (en) * 2017-06-27 2018-12-27 Florida Turbine Technologies, Inc. Additively Manufactured Blisk with Optimized Microstructure for Small Turbine Engines

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US5120373A (en) * 1991-04-15 1992-06-09 United Technologies Corporation Superalloy forging process
FR2703608A1 (fr) * 1993-04-07 1994-10-14 Aluminum Co Of America Procédé de fabrication de pièces forgées recristallisées de grande taille.
US5374323A (en) * 1991-08-26 1994-12-20 Aluminum Company Of America Nickel base alloy forged parts
US5413752A (en) * 1992-10-07 1995-05-09 General Electric Company Method for making fatigue crack growth-resistant nickel-base article
US5529643A (en) * 1994-10-17 1996-06-25 General Electric Company Method for minimizing nonuniform nucleation and supersolvus grain growth in a nickel-base superalloy
EP0726333A2 (fr) * 1994-07-07 1996-08-14 General Electric Company Procédé pour la production de superalliages à base de Ni
US5547523A (en) * 1995-01-03 1996-08-20 General Electric Company Retained strain forging of ni-base superalloys
US5891272A (en) * 1994-08-18 1999-04-06 General Electric Company Nickel-base superalloy having improved resistance to abnormal grain growth

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US6059904A (en) * 1995-04-27 2000-05-09 General Electric Company Isothermal and high retained strain forging of Ni-base superalloys
US5649280A (en) * 1996-01-02 1997-07-15 General Electric Company Method for controlling grain size in Ni-base superalloys
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Publication number Priority date Publication date Assignee Title
GB2225790A (en) * 1988-12-13 1990-06-13 Gen Electric Fatigue crack growth resistant nickel-base article and alloy and method of making.
US5120373A (en) * 1991-04-15 1992-06-09 United Technologies Corporation Superalloy forging process
US5374323A (en) * 1991-08-26 1994-12-20 Aluminum Company Of America Nickel base alloy forged parts
US5413752A (en) * 1992-10-07 1995-05-09 General Electric Company Method for making fatigue crack growth-resistant nickel-base article
FR2703608A1 (fr) * 1993-04-07 1994-10-14 Aluminum Co Of America Procédé de fabrication de pièces forgées recristallisées de grande taille.
EP0726333A2 (fr) * 1994-07-07 1996-08-14 General Electric Company Procédé pour la production de superalliages à base de Ni
US5891272A (en) * 1994-08-18 1999-04-06 General Electric Company Nickel-base superalloy having improved resistance to abnormal grain growth
US5529643A (en) * 1994-10-17 1996-06-25 General Electric Company Method for minimizing nonuniform nucleation and supersolvus grain growth in a nickel-base superalloy
US5547523A (en) * 1995-01-03 1996-08-20 General Electric Company Retained strain forging of ni-base superalloys

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2407565A1 (fr) * 2010-07-12 2012-01-18 Rolls-Royce plc Procédé pour améliorer les propriétés mécaniques d'un composant
US20130167979A1 (en) * 2011-12-29 2013-07-04 General Electric Company Method of predicting quench cracking in components formed by high deformation processes
CN107427896A (zh) * 2015-03-25 2017-12-01 日立金属株式会社 Ni基超耐热合金的制造方法
EP3287209A4 (fr) * 2015-03-25 2018-12-05 Hitachi Metals, Ltd. PROCÉDÉ DE PRODUCTION D'UN ALLIAGE À BASE DE Ni À TRÈS HAUTE RÉSISTANCE THERMIQUE
US10221474B2 (en) 2015-03-25 2019-03-05 Hitachi Metals, Ltd. Method of producing Ni-based superalloy

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US20110088817A1 (en) 2011-04-21

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