US20160333434A1 - Enhanced surface structure - Google Patents

Enhanced surface structure Download PDF

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Publication number
US20160333434A1
US20160333434A1 US15/112,640 US201515112640A US2016333434A1 US 20160333434 A1 US20160333434 A1 US 20160333434A1 US 201515112640 A US201515112640 A US 201515112640A US 2016333434 A1 US2016333434 A1 US 2016333434A1
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United States
Prior art keywords
composition
cast
recrystallized
forming
recrystallized layer
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Abandoned
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US15/112,640
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English (en)
Inventor
Howard B. Jones
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RTX Corp
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United Technologies Corp
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Publication date
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Priority to US15/112,640 priority Critical patent/US20160333434A1/en
Publication of US20160333434A1 publication Critical patent/US20160333434A1/en
Assigned to UNITED TECHNOLOGIES CORPORATION reassignment UNITED TECHNOLOGIES CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JONES, HOWARD B.
Assigned to RAYTHEON TECHNOLOGIES CORPORATION reassignment RAYTHEON TECHNOLOGIES CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: UNITED TECHNOLOGIES CORPORATION
Assigned to RAYTHEON TECHNOLOGIES CORPORATION reassignment RAYTHEON TECHNOLOGIES CORPORATION CORRECTIVE ASSIGNMENT TO CORRECT THE AND REMOVE PATENT APPLICATION NUMBER 11886281 AND ADD PATENT APPLICATION NUMBER 14846874. TO CORRECT THE RECEIVING PARTY ADDRESS PREVIOUSLY RECORDED AT REEL: 054062 FRAME: 0001. ASSIGNOR(S) HEREBY CONFIRMS THE CHANGE OF ADDRESS. Assignors: UNITED TECHNOLOGIES CORPORATION
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D6/00—Heat treatment of ferrous alloys
    • C21D6/02—Hardening by precipitation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D31/00—Cutting-off surplus material, e.g. gates; Cleaning and working on castings
    • B22D31/002—Cleaning, working on castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/011—Layered products comprising a layer of metal all layers being exclusively metallic all layers being formed of iron alloys or steels
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
    • C21D7/06—Modifying the physical properties of iron or steel by deformation by cold working of the surface by shot-peening or the like
    • 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
    • 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
    • C22F1/16—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of other metals or alloys based thereon
    • C22F1/18—High-melting or refractory metals or alloys based thereon
    • C22F1/183—High-melting or refractory metals or alloys based thereon of titanium or alloys based thereon

Definitions

  • the present disclosure relates to material compositions, more particularly to enhanced surface structure material compositions and methods of manufacturing the same.
  • Turbomachine components are often made from castings using methods such as a lost-wax cast procedure or other forming methods. After casting, some components may be shot-blasted and/or grit-blasted to remove shell material, oxides, and improve surface finish of the casting. As a consequence of this blasting, an uncontrolled amount of plastic deformation is introduced in to the surface of this material. If the casting is heat treated this surface layer can recrystallize and leave a fine grain region on the surface. However, because the plastic deformation is uncontrolled the depth of the plastic zone is uncontrolled and/or irregular which will lead to an uncontrolled/irregular amount of recrystallization at the surface. The present methods are very chaotic and do not control the depth or quality of recrystallization of the surface layer. Modification of the surface composition can be followed by a phase transformation. Examples include nitriding and carburizing of steels and diffusion coatings in Ni alloys.
  • a formed material includes a composition including a base non-recrystallized portion and a recrystallized layer of the composition having predetermined depth, the recrystallized layer forming at least part of a surface of the composition that overlays the non-recrystallized portion.
  • the recrystallized layer can be uniform in depth.
  • the depth of the recrystallized layer can be about 0.005 inches (about 0.127 mm) to about 0.025 inches (about 0.635 mm).
  • the recrystallized layer can include a smaller grain size than the base non-recrystallized portion of the composition.
  • the formed material is a turbomachine component.
  • a method of forming a material having an at least partially recrystallized layer includes forming a composition into a predetermined shape having a surface, wherein the forming leaves the surface of the composition in a non-recrystallized state, determining a desired depth of at least a portion of a recrystallized layer and recrystallizing at least a portion of the surface of the composition to form the recrystallized layer to the desired depth.
  • the recrystallizing step can further include heat treating the composition after a controlled plastic deformation of at least a portion of the surface of the composition to uniformly form the recrystallized layer.
  • the controlled plastic deformation can include at least one of shot-peening, controlled surface blasting, laser shot-peening, ultrasonic peening, explosion forming, or burnishing.
  • the method can further include cleaning the composition by shot-blasting the composition after forming.
  • the method can also further include precipitating at least one phase of the material by heat treating the composition to a desired temperature after forming and/or after or during cleaning.
  • the forming step can include casting.
  • a method includes casting a material into a cast having predetermined shape, removing the cast from the mold, cleaning the cast by shot-blasting, cold working a surface of the cast to facilitate recrystallization to desired depth, and then heat treating the cast to a suitable temperature to complete uniform recrystallization of the surface of the cast to a smaller grain size than the non-recrystallized portion.
  • the method can further include heat treating the cast at a suitable temperature to precipitate a phase of the material after removing the cast from the mold and before plastically deforming the surface of the cast to a desired depth.
  • FIG. 1 is a cross-sectional schematic view of a formed composition in accordance with this disclosure, showing a uniform recrystallized layer of a desired depth;
  • FIG. 2 is a cross-sectional schematic view of a formed composition in accordance with this disclosure, showing a predetermined recrystallized layer of a desired depth that covers only a portion of the non-recrystallized portion.
  • FIG. 1 An embodiment of a formed composition in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 100 .
  • FIG. 2 Another embodiment of a formed composition in accordance with the disclosure, or aspects thereof, is provided in FIG. 2 , as will be described.
  • the systems and methods described herein can be used to improve high cycle fatigue life and/or other desirable characteristics of machine components.
  • a formed material 100 includes a composition including a non-recrystallized portion 101 that is not processed to deliberately affect the crystal structure and/or grain size thereof.
  • the formed material 100 also includes a processed or recrystallized layer 103 of the composition with a predetermined depth “d”.
  • the term “recrystallized” means that the grain size and/or structure and/or other suitable material characteristics of the crystalline structure of the formed material have been modified from an initial formed condition (e.g., from the crystalline structure of a cast).
  • the recrystallized layer 103 has a smaller grain size than the non-recrystallized portion 101 .
  • the formed material 100 can be a cast, mold, or any other suitable type of manufacture that is formed in any suitable manner.
  • the composition can be any suitable material, including, but not limited to, one or more metals, one or more metal alloys, and/or any other suitable formable composition having a non-processed portion after forming.
  • the composition can include one or more of nickel, titanium, carbon, iron, steel, IN718, and/or the like.
  • the recrystallized layer 103 forms at least part of a surface 105 of the composition that overlays the non-recrystallized portion 101 .
  • the recrystallized layer 103 can be uniform in depth as shown in FIG. 1 .
  • a partial recrystallized layer 207 can form only a portion of the surface of a formed material 200 .
  • the depth of the recrystallized layer 103 can be any suitable depth “d”, including about 0.005 inches (about 0.127 mm) to about 0.025 inches (about 0.635 mm). In some embodiments, the suitable depth “d” is about 0.010 inches (about 0.254 mm). Depth “d” can be about 1 to about 4 times as deep as layers inadvertently formed via known shot-blasting techniques. As disclosed herein, the recrystallized layer 103 can include a smaller grain size than a non-recrystallized portion 101 of the formed material 100 . In some embodiments, the formed material can be a turbomachine component such as, but not limited to, compressor rotor blades, stator blades, cases, and/or housings.
  • a turbomachine component such as, but not limited to, compressor rotor blades, stator blades, cases, and/or housings.
  • a method of forming a material having an at least partially recrystallized layer 103 includes forming a composition into a predetermined shape having a surface 105 .
  • the forming leaves at least a portion of the surface 105 of the composition in a non-processed and/or non-recrystallized state.
  • the forming step can be a casting process (e.g. lost-wax casting), a molding process, additive manufacturing, powder bed fusion, or any other suitable manufacturing process.
  • the method can also include cleaning the formed composition via any suitable method including shot blasting.
  • the method can also include determining a desired depth “d” of at least a portion of a recrystallized layer 103 .
  • Certain material characteristics e.g. high cycle fatigue, low cycle fatigue
  • desired material characteristics can be achieved by selecting a desired depth “d” and/or a desired uniformity of a recrystallized layer 103 after forming.
  • the method can also include precipitation hardening reactions or recrystallizing at least a portion of the recrystallized layer 103 to the desired depth “d”.
  • the recrystallizing step includes controlling a plastic deformation of the composition at the surface.
  • the plastic deformation can include at least one of shot-peening, controlled surface blasting, laser shot-peening, ultrasonic peening, and/or burnishing such that the depth of plastic deformation is controlled to cause formation of recrystallized layer 103 of a desired depth “d”.
  • the method can further include heat treating the composition to control intermediate phase reactions such as the precipitation of delta phase in IN718.
  • the heat treating can be done after forming and/or during or after cleaning the formed material via, e.g., shot-blasting, and/or during any other suitable time.
  • the heat treatment can be configured to cause precipitation of desired second phases of material (e.g. ⁇ -phase at about 1550 deg. F, ⁇ ′, ⁇ ′′, carbide-phases, etc.).
  • Heat treating the composition to precipitate phases of the composition can occur at any suitable temperature and/or series of temperatures to cause precipitation of the desired phases. In some embodiments, the precipitation of second phases results in less grain size growth and facilitates recrystallization to a smaller grain size.
  • Hot isostatic pressing can also be performed on the composition to reduce porosity of the composition.
  • the method can include heat treating the formed material 100 to facilitate one or more of recrystallization, reduction in grain size, and/or any other suitable material modification to achieve a desired recrystallized layer 103 .
  • the formed material 100 may be exposed to a desired consistent and/or varying temperature during the manufacturing process to facilitate recrystallization at a desired depth “d” and/or to a desired grain size.
  • a method includes casting a material into a cast having predetermined shape, removing the cast from the mold, then cleaning the cast by shot-blasting, then cold working a surface of the cast to facilitate recrystallization to desired depth, and then heat treating the cast to a suitable temperature to complete uniform recrystallization of the surface of the cast to a smaller grain size than the non-recrystallized portion.
  • the method can further include heat treating the cast at a suitable temperature to precipitate a phase of the material after removing the cast from the mold and before plastically deforming the surface of the cast to a desired depth.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
US15/112,640 2014-01-28 2015-01-07 Enhanced surface structure Abandoned US20160333434A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US15/112,640 US20160333434A1 (en) 2014-01-28 2015-01-07 Enhanced surface structure

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201461932562P 2014-01-28 2014-01-28
PCT/US2015/010404 WO2015116352A1 (en) 2014-01-28 2015-01-07 Enhanced surface structure
US15/112,640 US20160333434A1 (en) 2014-01-28 2015-01-07 Enhanced surface structure

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EP (1) EP3099482B1 (de)
WO (1) WO2015116352A1 (de)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB201500713D0 (en) 2015-01-16 2015-03-04 Cummins Ltd A method for manufacturing a turbine wheel
GB201615671D0 (en) * 2016-09-15 2016-11-02 Rolls Royce Plc A method of manufacturing a component from a nickel-based superalloy

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2067076A (en) * 1934-02-14 1937-01-05 Aluminum Co Of America Method of controlling grain structure in alloys and articles produced thereby
JPS60149717A (ja) * 1984-01-17 1985-08-07 Kobe Steel Ltd 鋳片を素材とする熱間押出材の製造方法
US4799974A (en) * 1987-05-27 1989-01-24 Rockwell International Corporation Method of forming a fine grain structure on the surface of an aluminum alloy
US5122205A (en) * 1989-04-25 1992-06-16 Yoshida Kogyo K.K. Corrosion resistant aluminum-based alloy
US6342110B1 (en) * 1996-03-01 2002-01-29 Integran Technologies Inc. Lead and lead alloys with enhanced creep and/or intergranular corrosion resistance, especially for lead-acid batteries and electrodes therefor
US6344097B1 (en) * 2000-05-26 2002-02-05 Integran Technologies Inc. Surface treatment of austenitic Ni-Fe-Cr-based alloys for improved resistance to intergranular-corrosion and-cracking
US20080274671A1 (en) * 2006-09-11 2008-11-06 Enbio Limited Method of doping surfaces
US20100319820A1 (en) * 2007-02-13 2010-12-23 Hisanori Koma Process for producing aluminum alloy material and heat treated aluminum alloy material
US8323427B1 (en) * 2009-09-14 2012-12-04 The Boeing Company Engineered shapes from metallic alloys
US20150122379A1 (en) * 2013-11-06 2015-05-07 Industry-Academic Cooperation Foundation, Yonsei University Magnesium alloy for precipitation strengthening extrusion and method of manufacturing the same

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1127157A (en) * 1966-06-13 1968-09-11 Orenda Ltd Method for improving the fatigue resistance of turbine blades
EP0115092B1 (de) * 1983-02-01 1987-08-12 BBC Brown Boveri AG Bauteil mit hoher Korrosions- und Oxydationsbeständigkeit, bestehend aus einer dispersionsgehärteten Superlegierung und Verfahren zu dessen Herstellung
DE3664930D1 (en) * 1985-03-15 1989-09-14 Bbc Brown Boveri & Cie Process for enhancing the oxidation and corrosion resistance of a component made from a dispersion-hardened superalloy by means of a surface treatment
US4969593A (en) * 1988-07-20 1990-11-13 Grumman Aerospace Corporation Method for diffusion bonding of metals and alloys using mechanical deformation
CA2141775A1 (en) * 1994-09-02 1996-03-03 Murray W. Mahoney Process for imparting a localized fine grain microstructure to selected surfaces in aluminum alloys
US5966592A (en) * 1995-11-21 1999-10-12 Tessera, Inc. Structure and method for making a compliant lead for a microelectronic device
DE19756354B4 (de) * 1997-12-18 2007-03-01 Alstom Schaufel und Verfahren zur Herstellung der Schaufel
JP5767080B2 (ja) * 2011-06-21 2015-08-19 三菱日立パワーシステムズ株式会社 耐熱合金部材及びその製造方法、耐熱合金部材の補修方法

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2067076A (en) * 1934-02-14 1937-01-05 Aluminum Co Of America Method of controlling grain structure in alloys and articles produced thereby
JPS60149717A (ja) * 1984-01-17 1985-08-07 Kobe Steel Ltd 鋳片を素材とする熱間押出材の製造方法
US4799974A (en) * 1987-05-27 1989-01-24 Rockwell International Corporation Method of forming a fine grain structure on the surface of an aluminum alloy
US5122205A (en) * 1989-04-25 1992-06-16 Yoshida Kogyo K.K. Corrosion resistant aluminum-based alloy
US6342110B1 (en) * 1996-03-01 2002-01-29 Integran Technologies Inc. Lead and lead alloys with enhanced creep and/or intergranular corrosion resistance, especially for lead-acid batteries and electrodes therefor
US6344097B1 (en) * 2000-05-26 2002-02-05 Integran Technologies Inc. Surface treatment of austenitic Ni-Fe-Cr-based alloys for improved resistance to intergranular-corrosion and-cracking
US20080274671A1 (en) * 2006-09-11 2008-11-06 Enbio Limited Method of doping surfaces
US20100319820A1 (en) * 2007-02-13 2010-12-23 Hisanori Koma Process for producing aluminum alloy material and heat treated aluminum alloy material
US8323427B1 (en) * 2009-09-14 2012-12-04 The Boeing Company Engineered shapes from metallic alloys
US20150122379A1 (en) * 2013-11-06 2015-05-07 Industry-Academic Cooperation Foundation, Yonsei University Magnesium alloy for precipitation strengthening extrusion and method of manufacturing the same

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EP3099482A1 (de) 2016-12-07
WO2015116352A1 (en) 2015-08-06
EP3099482B1 (de) 2020-02-26
EP3099482A4 (de) 2017-08-02

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