Effect of near isothermal forging on the microstructure of Ti_3Al/TC11 welding interface

The as-forged Ti3Al-based alloy and TC11 titanium alloy were welded by electron beams in vacuum, and then they were processed using near isothermal forging and gradient heat treatment. The experimental results show that the near isothermal forging processing parameters have little effect on the phase constitution of the weld. The weld consists of Ti2AlNb, MoNb, Nb3Al, and TiAl3 phases as well as the two main phases of α and α2. However, the near isothermal forging processing parameters have significant effect on the shape, size, and volume fraction of α and α2 phases of the welding interface. The sizes of the α and α2 phases increase as the strain rate decreases. Because the distortion energy of the lattice and the volume fraction of the grains occurring in dynamic recrystallization increase with an increase in deformation, the sizes of the α and α2 phases of the welding interface decrease.

Experimental Investigation and Numerical Simulation of the Grain Size Evolution during Isothermal Forging of a TC6 Alloy

Hot compression was conducted at a Thermecmaster-Z simulator, at deformation temperatures of 800-1040℃, with strain rates of 0.001-50 s-1 and height reduction of 50%. Grain size of the prior α phase was measured with a Leica LABOR-LUX12MFS/ST microscope to which QUANTIMET 500 software for image analysis for quantitative metallography was linked. According to the present experimental data, a constitutive relationship for a TC6 alloy and a model for grain size of the prior a phase were established based on the Arrhenius' equation and the Yada's equation, respectively. By finite element (FE) simulation, deformation distribution was determined for isothermal forging of a TC6 aerofoil blade at temperatures of 860-940℃ and hammer velocities of 9-3000.0 mm/min. Meanwhile, the grain size of the prior α phase is simulated during isothermal forging of the TC6 aerofoil blade, by combining FE outputs with the present grain size model. The present results illustrate the grain size and its distribution in the prior α phase during the isothermal forging of the TC6 aerofoil blade. The simulated results show that the height reduction, deformation temperature, and hammer velocity have significant effects on distribution of the equivalent strain and the grain size of the prior α phase.

Isothermal forging process design for spray-formed FGH95 superalloy turbine disk based on numerical simulation

Based on the experimental data from hot compression tests on Gleeble 1500 thermal simulator, the revised constitutive equations of spray-formed FGH95 superalloy considering the effect of strain on the material constants were established. The average absolute relative error （AARE） was employed to verify the validity of the constitutive equation, and the value of AARE is 3.85 %. Subsequently, the revised constitutive equations were successfully used to simulate and analyze the deformation behavior, stress distribution, forming loads and temperature distribution in both dies and billet during the isothermal forging process of turbine disk of large dimension （about 400 mm in diameter） by the means of finite element method （FEM）. Moreover, the optimum process parameters are 1,120 ℃ of forging temperature and 0.01 s^-1 of strain rate for the spray-formed FGH95 superalloy turbine disk.

A phenomenological constitutive equation for Rene 95 PM alloy and its application to isothermal forging process of turbine disk

The flow behavior of Rene 95 PM alloy was studied from 1050 to 1150 deg Cwith strain rate of 1 X 10^(-3), 1 X 10^(-2), 1 X 10^(-1) and 1 s^(-1). At a given temperature andstrain rate, flow curves exhibit a peak followed by flow softening up to a steady state. Moreover,at constant strain, flow stress increases with increasing strain rate and decreasing temperature. Anequation relating hyperbolic sine of flow stress to hot working parameters, such as strain, strainrate and temperature, was established by using multiple nonlinear regression method. A very goodagreement was found between predicted and experimental flow stress in all the strain rangeinvestigated. Application of the constitutive equation in predicting forming loads and flow behaviorand temperature distribution in both upper and lower dies in an isothermal forging process ofturbine disk of large dimension (about 630 mm) by means of a finite element code was systematicallyanalyzed.

Analysis of isothermal forging process and mechanical properties of complex aluminum forging for aviation

Large complex 7A85 aluminum wing-body joint was forged employing isothermal forging process and its mechanical properties were studied.The tensile strength after forging is up to 587.5 MPa in longitudinal direction,15% higher than that using free forging.Moreover,the tensile strength of the forging is almost the same in three directions.Isothermal forging also performs well on overall fracture toughness,with a maximum value of 39.8 MPa·m1/2,and that of short transverse direction all reaches 36 MPa·m1/2 and above,with a maximum relative error of only 3.6%.The results indicate that the isothermal forging leads to better performance as well as higher uniformity in mechanical properties.

Effect of Isothermal Forging on the Microstructure and Mechanical Properties of Mg-8Gd-3Y-0.5Zr Alloy

Aiming at the problems of poor plastic forming ability,narrow forging temperature range,and strain rate sensitivity of rare earth magnesium alloys,a study on the microstructure and mechanical properties of Mg-8Gd-3Y-0.5Zr alloy with different isothermal forging processes is carried out.The microstructure and properties of the alloy in the as-cast,isothermal forged,and post-aging states after forging are studied with optical microscope(OM),scanning electron microscope(SEM),and tensile testing.The results show that significant dynamic recrystallization occurs during the isothermal forging process,a fine equiaxed grain structure is formed,and the mechanical properties of the alloy are greatly improved.When the isothermal forging temperature is 460℃ and the strain rate is 0.02 s^(-1),the alloy structure performance is the best,the room temperature tensile yield strength(TYS)is 218 MPa,the ultimate tensile strength(UTS)is 299 MPa,and the fracture elongation(FE)is 19.2%.When the alloy is post-forging artificial aged,theα-Mg matrix is dispersed,the Mg_5(Gd,Y)phase is precipitated,the UTS of the alloy is increased to 392 MPa,and the FE is reduced to 12.0%.

Microstructure and tensile properties of isothermally forged Ni–43Ti–4Al–2Nb–2Hf alloy

NiTi-Al-based alloys are promising high-tem- perature structural materials for aerospace and astronautics applications. A new NiTi-Al-based alloy Ni--43Ti-4AI- 2Nb-2Hf （at%） was processed via isothermal forging. The microstructure and mechanical properties at room temperature and high temperature were investigated through scanning electron microscope （SEM）, X-ray diffraction （XRD）, and tensile tests. Results show that the micro- structure of as-forged Ni-43Ti--4AI-2Nb-2Hf alloy con- sists of NiTi matrix, Ti2Ni phase, and Hf-rich phase. The simultaneous addition of Nb and Hf, which have strong affinities for Ti sites, promotes the precipitation of Hf-rich phases along the grain boundaries. The tensile strengths of Ni-43Ti-4A1-2Nb-2Hf alloy are dramatically increased compared with the ternary Ni-46Ti-4A1 alloy. At room temperature and 650℃, the yield stress of Ni--43Ti-4Al- 2Nb-2Hf alloy reaches 1,070 and 610 MPa, respectively, which are 30 % and 150 % higher than those of Ni--46Ti- 4Al alloy. The improved tensile property results from the solid solution strengthening by Nb and Hf, as well as the dispersion hardening of the Ti2Ni and Hf-rich phases.

Developments and perspectives on the precision forming processes for ultra-large size integrated components

In order to meet the requirements of high reliability,long-lifetime and lightweight in a new generation of aerospace,aviation,high-speed train,and energy power equipment,integrated components are urgently needed to replace traditional multi-piece,welded components.The applications of integrated components involve in a series of large-size,complex-shaped,highperformance components made of difficult-to-deform materials,which present a huge challenge for forming ultra-large size integrated components.In this paper,the developments and perspectives of several extreme forming technologies are reviewed,including the sheet hydroforming of ultra-large curved components,dieless hydroforming of ellipsoidal shells,radial-axial ring rolling of rings,in situ manufacturing process of flanges,and local isothermal forging of titanium alloy components.The principle and processes for controlling deformation are briefly illustrated.The forming of typical ultra-large size integrated components and industrial applications are introduced,such as the high strength aluminum alloy,3m in diameter,integrated tank dome first formed by using a sheet blank with a thickness the same as the final component,and a 16m diameter,integrated steel ring rolled by using a single billet.The trends for extreme forming of ultra-large size integrated components are discussed with a goal of providing ideas and fundamental guidance for the further development of new forming processes for extreme-size integrated components in the future.

Design for Isothermal Forging of Ti-46.5Al-2.5V-1.0Cr-0.3Ni Alloy

The three-dimensional finite element method was utilized to investigate the isothermal forging of Ti-46.5Al-2.5V-1.0Cr-0.3Ni（atomic percent,%）alloy.The partition of height reduction,effective strain,and damage of the alloy during the forging were analyzed.The simulation results were verified by experiments.The results show that large plastic deformation can improve the homogeneity of the deformed microstructure and the higher accumulative height reduction can be achieved through two-step forging.With the isothermal forging of two-step reduction of 60%＋62.5%（total height reduction of 85%）,the entire forged pancake can acquire refined microstructure and expand the uniform flow zone to almost the entire volume.

Progress in the Research and Manufacture of GH4169 Alloy

GH4169 alloy has been widely used in fields such as aviation, aerospace, and petrochemical, because of its excellent combination of mechanical and processing properties. These properties include good high-temperature strength, excellent creep and fatigue resistance, and good processing and welding performance. The requirement for high performance, high reliability, and long service life of modem engines has led to the incentive to develop GH4169 alloys with improved performance, such as increased temperature-bearing capacity, improved creep endurance, and better fatigue resistance. Advances during the past thirty years in ba- sic research and industrial technology related to GH4169 alloy were systematically summarized, including advances in alloy modi- fication, melting process optimization, and hot deformation technology.