method of refining a grain size of a workpiece comprising a selected titanium metal material and a t

专利摘要:
processing routes for titanium and titanium alloys. methods of refining the grain size of titanium and titanium alloys include multi-axis forging of high thermally controlled rate of deformation. a high strain rate adiabatically heats an internal region of the workpiece during forging and a thermal control system is used to heat an external surface region to the workpiece forging temperature, while the internal region is allowed to cool to workpiece forging temperature. an additional method includes stretch and multiple pressure forging of titanium or a titanium alloy using a lower strain rate than is used in conventional open die forging of titanium and titanium alloys. incremental rotation of workpiece and forging by stretching causes severe plastic deformation and grain cooling in the forging of titanium or titanium alloy.
公开号:BR112013005795B1
申请号:R112013005795
申请日:2011-08-22
公开日:2019-12-17
发明作者:Thomas Jean-Philippe；V Mantione John；Mark Davis R；S Minisandram Ramesh；L Kennedy Richard；M Forbes Jones Robin；J De Souza Urban
申请人:Ati Properties Llc；Ati Properties Inc；
IPC主号:

专利说明:

“METHOD OF REFINING A GRAIN SIZE OF A WORKPLACE UNDERSTANDING A SELECTED METAL MATERIAL OF TITANIUM AND A TITANIUM ALLOY” [001] Declaration regarding the federal government sponsored development and research.
[002] The present invention was made with the support of the US Government in accordance with NIST Contract number 70NANB7H7038, granted by the National Institute of Standards and Technology (NIST), Department of Commerce of the United States of America. The United States Government may have certain rights in the invention.
Technology background
Field of technology [003] The present disclosure is directed to forging methods for titanium and titanium alloys and to apparatus for carrying out such methods.
Description of technology background [004] Methods for producing titanium and titanium alloys having coarse grain (CG), fine grain (FG), very fine grain (VFG), or ultra fine grain (UFG) microstructure involve the use of multiple reheating and forging steps. Forging steps can include one or more pressure forging steps in addition to drawing the forge in an open die press.
[005] As used here, when referring to the microstructure of titanium and titanium alloy: the term "coarse grain" refers to alpha grain sizes from 400 pm to greater than approximately 14 pm; the term “fine grain” refers to alpha grain sizes in the range of 14 pm to greater than 10 pm; the term "very fine grain" refers to alpha grain sizes from 10 pm to greater than 4.0 pm; and the term "ultrafine grain" refers to alpha grain sizes of 4.0 pm or less.
[006] Known commercial methods of forging titanium and titanium alloys for
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2/54 producing coarse-grained (CG) or fine (FG) microstructures employ strain rates from 0.03 s ^-1 to 0.10 s ^-1 using multiple reheating and forging steps.
[007] Known methods for the manufacture of fine-grained (FG), very fine (VFG) or ultra-fine (UFG) microstructures apply a multi-axis forging (MAF) process at an ultra-slow strain rate of 0.001 s ^-1 or slower (see G. Salishchev, et al., Materials Science Forum, vol. 584-586, p. 783-788 (2008)). The generic MAF process is described in C. Desrayaud, et al., Journal of Materials Processing Technology, 172, p. 152-156 (2006).
[008] The key to grain refinement in the ultra slow deformation rate MAF process is the ability to operate continuously in a dynamic recrystallization regime that is a result of the ultra slow deformation rates used, that is, 0.001 s ^{- 1} or slower. During dynamic recrystallization, grains nuclei simultaneously, grow and accumulate disagreements. The generation of discrepancies in the newly nucleated grains continuously reduces the driving force for grain growth and the grain nucleation is energetically favorable. The ultra slow deformation rate MAF process uses dynamic recrystallization to continuously recrystallize grains during the forging process.
[009] Relatively uniform UFG Ti-6-4 alloy cubes can be produced using the ultra-slow strain rate MAF process, however the cumulative time it takes to perform the MAF can be excessive in a commercial setting. In addition, commercially available, large-scale, conventional open die press forging equipment may not be able to achieve the ultralent strain rates required in such modalities and, therefore, custom forging equipment may be required for MAF of ultralent deformation rate in production scale.
[0010] Therefore, it would be advantageous to develop a process for
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3/54 produce titanium and titanium alloys having a coarse, fine, very fine or ultrafine grain microstructure that does not require multiple reheating and / or accommodates higher strain rates, reduces processing time and eliminates the need for forging equipment on request.
Summary [0011] According to one aspect of the present disclosure, a method of refining the grain size of a workpiece comprising a selected metallic material of titanium and a titanium alloy comprises heating the workpiece to a forging temperature of workpiece in an alpha + beta phase field of the metallic. The workpiece is then forged on multiple axes. Multi-axis forging comprises press-forging the workpiece at the workpiece forging temperature in the direction of a first orthogonal geometric axis of the workpiece with a deformation rate sufficient to adiabatically heat an internal region of the workpiece. Forging in the direction of the first orthogonal geometry axis is followed by allowing the adiabatically heated inner region of the workpiece to cool to the workpiece forging temperature, while heating a workpiece outer surface region to the forging temperature workpiece. The workpiece is then press-forged at the workpiece forging temperature in the direction of a second orthogonal geometric axis of the workpiece with a deformation rate that is sufficient to adiabatically heat the internal region of the workpiece. Forging in the direction of the second orthogonal geometry axis is followed by allowing the adiabatically heated inner region of the workpiece to cool to the workpiece forging temperature, while heating a workpiece outer surface region to the forging temperature workpiece. The workpiece is then press-forged at the workpiece forging temperature in the direction of a third axis
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4/54 orthogonal geometric shape of the workpiece with a deformation rate that is sufficient to adiabatically heat the internal region of the workpiece. Forging in the direction of the third orthogonal geometric axis is followed by allowing the adiabatically heated inner region of the workpiece to cool down to the workpiece forging temperature, while heating a workpiece outer surface region to the forging temperature workpiece. Press forging and permitting steps are repeated until a deformation of at least 3.5 is achieved in at least one region of the titanium alloy workpiece. In a non-limiting mode, a strain rate used during press forging is in the range of 0.2 s ^-1 to 0.8 s ^-1 , inclusive.
[0012] According to another aspect of the present disclosure, a method of refining a workpiece's grain size comprising a metallic material selected from titanium and titanium alloy comprises heating the workpiece to a workpiece forging temperature in an alpha + beta phase field of the metallic material. In non-limiting modalities, the workpiece comprises a cylindrical-like shape and a dimension in starting cross-section. The workpiece is forged by pressure at the workpiece forging temperature. After compression, the workpiece is forged by multi-pass traction at the workpiece forging temperature. The multi-pass stretch forging comprises incrementally rotating the workpiece in a rotational direction followed by stretching forging the workpiece after each rotation. The incremental rotation and stretching forging of the workpiece are repeated until the workpiece comprises substantially the same dimension in the starting cross section of the workpiece. In a non-limiting mode, a strain rate used in pressure forging is stretching forging is in the range of 0.001 s ^-1 to 0.002 s ^-1 , inclusive.
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[0013] According to an additional aspect of the present disclosure, a method for forging multiple isothermal forging of a workpiece comprising a metallic material selected from a metal and a metal alloy comprises heating the workpiece to a workpiece forging temperature. The workpiece is forged at the workpiece forging temperature at a deformation rate sufficient to adiabatically heat an internal region of the workpiece. The inner region of the workpiece is allowed to cool down to the workpiece forging temperature, while an outer surface region of the workpiece is heated to the workpiece forging temperature. The steps of forging the workpiece and allowing the inner region of the workpiece to cool while heating the outer surface region of the metal alloy are repeated until a desired characteristic is obtained.
Brief description of the drawings [0014] The aspects and advantages of the apparatus and methods described here can be better understood by reference to the attached drawings in which:
[0015] Figure 1 is a flow chart listing steps of a non-limiting modality of a method according to the present disclosure to process titanium and titanium alloys for grain size refinement;
[0016] Figure 2 is a schematic representation of a non-limiting modality of a high-deformation rate multi-axis forging method using thermal control to process titanium and titanium alloys for the refinement of grain sizes, in which the figures 2 (a), 2 (c), and 2 (e) represent unrestricted press forging steps, and figures 2 (b), 2 (d) and 2 (f) represent non-limiting cooling and heating steps according to non-limiting aspects of this disclosure;
[0017] Figure 3 is a schematic representation of a forging technique
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6/54 multiple axes of slow strain rate known to be used to refine small scale sample grains;
[0018] Figure 4 is a schematic representation of a graph of thermomechanical process of time-temperature for a non-limiting modality of a method of forging multiple axes of high strain rate according to the present disclosure;
[0019] Figure 5 is a schematic representation of a graph of thermomechanical process of time-temperature for a non-limiting modality of a method of forging multiple axes of high strain rate of multiple temperatures according to the present disclosure;
[0020] Figure 6 is a schematic representation of a graph of thermomechanical time-temperature process for a non-limiting modality of a method of forging multiple axes of high strain rate using beta transus according to the present disclosure;
[0021] Figure 7 is a schematic representation of a non-limiting modality of a multiple pressure and traction method for grain size refinement according to the present disclosure;
[0022] Figure 8 is a flow chart listing steps of a non-limiting modality of a method according to the present disclosure to process by pressing and stretching multiple titanium and titanium alloys to refine grain size;
[0023] Figure 9 is a thermomechanical graph of time-temperature for the non-limiting modality of example 1 of this disclosure;
[0024] Figure 10 is a micrograph of the beta annealed material of example 1 showing equiaxial grains with grain sizes between 10-30 μm;
[0025] Figure 11 is a micrograph of a central region of the sample forged a-b-c of example 1;
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7/54 [0026] Figure 12 is a prediction of finite element modeling of internal region cooling times according to a non-limiting mode of this disclosure;
[0027] Figure 13 is a micrograph of the center of a cube after processing according to the non-limiting method described in example 4;
[0028] Figure 14 is a photograph of a cross section of a cube processed according to example 4;
[0029] Figure 15 represents the results of finite element modeling to simulate deformation in thermally controlled multi-axis forging of a cube processed according to example 6;
[0030] Figure 16 (a) is a micrograph of a cross section from the center of the sample processed according to example 7; figure 16 (b) is a cross section from the surface close to the sample processed according to example 7;
[0031] Figure 17 is a schematic thermomechanical time-temperature graph of the process used in example 9;
[0032] Figure 18 is a macro-photograph of a cross section of a sample processed according to the non-limiting modality of example 9;
[0033] Figure 19 is a micrograph of a sample processed according to the non-limiting modality of example 9 showing the very fine grain size; and [0034] Figure 20 represents a simulation of fine element deformation modeling of the sample prepared in the non-limiting modality of example 9.
[0035] The reader will recognize the above details, as well as others, after considering the detailed description below of certain non-limiting modalities in accordance with the present disclosure.
Detailed description of certain non-limiting modalities
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8/54 [0036] In the present description of non-limiting modalities, different from operational examples or where otherwise indicated, all numbers expressing quantities or characteristics should be understood as being modified in all cases by the term "approximately". Therefore, unless otherwise stated, any numerical parameters set out in the following description are approximations that may vary depending on the desired properties sought to be obtained by the methods according to the present disclosure. At a minimum and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter must at least be interpreted in light of the number of significant digits reported and by applying common rounding techniques.
[0037] Any patent, publication or other disclosure material, in whole or in part, that is said to be incorporated by reference here is incorporated here only to the extent that the incorporated material does not conflict with existing definitions, statements or other disclosure material exposed in that disclosure. As such, and to the extent necessary, the disclosure as set forth herein replaces any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference here, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, is incorporated only to the extent that no conflict originates between that material. embedded material and existing disclosure material.
[0038] One aspect of the present disclosure includes non-limiting modalities of a multi-axis forging process that includes using high strain rates during the forging steps to refine the grain size in titanium and titanium alloys. These method modalities are generically referred to in this disclosure as "high strain rate multiple axis forging" or "high strain rate MAF".
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9/54 [0039] Referring now to the flowchart in figure 1, and the schematic representation in figure 2, in a non-limiting mode according to the present disclosure, a method 20 using a multi-axis forging (MAF) process of high strain rate to refine the grain size of titanium or titanium alloys is represented. Multi-axis forging (26), also known as “abc” forging, which is a form of severe plastic deformation, includes heating (step 22 in figure 1) a workpiece comprising a metallic material selected from titanium and titanium alloy 24 at a workpiece forging temperature in an alpha + beta phase field of the metallic material, followed by MAF 26 using a high strain rate.
[0040] As will be evident from a consideration of the present disclosure, a high strain rate is used in high strain rate MAF to adiabatically heat an internal region of the workpiece. However, in a non-limiting modality according to this disclosure, at least in the last sequence of high strain rate MAF abc strokes, the temperature of the inner region of the titanium or titanium alloy 24 workpiece must not exceed the temperature beta-transus (Tp) of the titanium or titanium alloy workpiece. Therefore, the workpiece forging temperature at least for the final abc sequence of high strain rate MAF strokes should be chosen to ensure that the temperature of the workpiece inner region during high strain rate MAF is not equal to or exceeds the beta-transus temperature of the metallic material. In a non-limiting mode according to this disclosure, the temperature of the internal region of the workpiece does not exceed 20 ° F (11.1 ° C) below the beta transus temperature of the metallic material, that is, Tp - 20 ° C ( Tp -11.1 ° C) for at least the sequence of final high strain rate of strokes MAF abc.
[0041] In a non-limiting deformation rate MAF modality
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10/54 elevated according to this disclosure, a workpiece forging temperature comprises a temperature in a workpiece forging temperature range. In a non-limiting mode, the workpiece forging temperature is in a workpiece forging temperature range of 100 ° F (55.6 ° C) below the beta transus (Tp) temperature of titanium metal material or titanium alloy up to 700 ° F (388.9 ° C) below the beta transus temperature of the titanium metal material or titanium alloy. In yet another non-limiting mode, the workpiece forging temperature is in a temperature range of 300 ° F (166.7 ° C) below the beta transus temperature of titanium or titanium alloy up to 625 ° F (347 ° C) below the beta transition temperature of titanium or titanium alloy. In a non-limiting mode, the low end of a workpiece forging temperature range is a temperature in the alpha + beta phase field where substantial damage does not occur to the workpiece surface during the forging stroke, as would be known by a person with common knowledge in the art.
[0042] In a non-limiting mode, the workpiece forging temperature range when applying the mode of the present disclosure in figure 1 to a Ti-6-4 alloy (Ti-6Al-4V; UNS R56400) that has a beta transus (Tp) temperature of approximately 1850 ° F (1010 ° C), it can be 1150 ° F (621.1 ° C) to 1750 ° F (954.4 ° C), or in another mode it can be 1225 ° F (662.8 ° C) to 1550 ° F (843.3 ° C).
[0043] In a non-limiting mode, before heating 22 the titanium or titanium alloy 24 workpiece at a workpiece forging temperature in the alpha + beta phase field, the workpiece 24 is optionally annealed beta and air-cooled (not shown). Beta annealing comprises heating the workpiece 24 above the beta transus temperature of the titanium or titanium alloy metal material and retaining it long enough to form the entire beta phase in the
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11/54 work piece. Beta annealing is a well-known process and is therefore not described in further detail here. A non-limiting mode of beta annealing may include heating the workpiece 24 to a beta soak temperature of approximately 50 ° F (27.8 ° C) above the beta transus temperature of the titanium or titanium alloy and retaining the workpiece 24 at temperature for approximately 1 hour.
[0044] Referring again to figures 1 and 2, when the workpiece comprising a metallic material selected from titanium and titanium alloy 24 is at the workpiece forging temperature, the workpiece is subjected to the MAF rate of high deformation (26). In a non-limiting mode according to this disclosure, MAF 26 comprises press forging (step 28, and shown in figure 2 (a)) the workpiece 24 at the workpiece forging temperature in the direction (A) of a first orthogonal geometric axis 30 of the workpiece using a strain rate which is sufficient to heat the workpiece adiabatically, or at least heat adiabatically an internal region of the workpiece, and to plastically deform the workpiece 24. limiting this disclosure, the phrase "inner region" as used here refers to an inner region including a volume of approximately 20%, or approximately 30%, or approximately 40% or approximately 50% of the volume of the cube.
[0045] High strain rates and fast plunger speeds are used to adiabatically heat the workpiece's internal region in non-limiting high strain rate MAF modalities according to this disclosure. In a non-limiting mode according to this disclosure, the term "high strain rate" refers to a range of strain rate from approximately 0.2 s ^-1 to approximately 0.8 s ^-1 , inclusive. In another non-limiting modality according to this disclosure, the term “deformation rate
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12/54 high ”as used here refers to a strain rate of approximately 0.2 s ^-1 to approximately 0.4 s ^-1 , inclusive.
[0046] In a non-limiting embodiment according to this disclosure, using a high strain rate as defined above, the inner region of the titanium or titanium alloy workpiece can be adiabatically heated up to approximately 200 ° F above the temperature of workpiece forging. In another non-limiting mode, during press forging the internal region is adiabatically heated to approximately 100 ° F (55.6 ° C) to 300 ° F (166.7 ° C) above the workpiece forging temperature. In yet another non-limiting mode, during press forging the internal region is adiabatically heated to approximately 150 ° F (83.3 ° C) to 250 ° F (138.9 ° F) above the workpiece forging temperature. As noted above, no portion of the workpiece should be heated above the beta transus temperature of the titanium or titanium alloy during the last sequence of high strain rate MAF a-b-c strokes.
[0047] In a non-limiting mode, during press forging (28) the workpiece 24 is plastically deformed to a reduction of 20% to 50% in height or other dimension. In another non-limiting modality, during forging of press (28) the titanium alloy workpiece 24 is plastically deformed to a reduction of 30% to 40% in height or other dimension.
[0048] A process of forging multiple axes of known slow deformation rate is represented schematically in figure 3. Generally, an aspect of forging multiple axes is that after all three strokes or “blows” of the forging apparatus, as a forging open die, the shape of the workpiece approaches that of the workpiece just before the first stroke. For example, after a 5-inch side cubic workpiece it is initially forged with a first “stroke” in the direction of the geometric axis “a”, rotated 90 °
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13/54 and forged with a second stroke in the direction of the geometric axis "b", and rotated 90 ° and forged with a third stroke in the direction of the geometric axis "c", the workpiece will resemble the starting cube with sides of 5 inches.
[0049] In another non-limiting modality, a first stage of press forging 28, shown in figure 2 (a), also referred to here as the “first stroke”, may include forging the workpiece's press on an upper face for down to a predetermined spacer height while the workpiece is at a workpiece forging temperature. A predetermined spacer height of a non-limiting embodiment is, for example, 5 inches. Other spacer heights, such as, for example, less than 5 inches, approximately 3 inches, greater than 5 inches, or 5 inches up to 30 inches are included in the scope of the present disclosure. Larger spacer heights are only limited by the capabilities of the forge and, as will be seen here, the capabilities of the thermal control system according to the present disclosure. Spacer heights less than 3 inches are also included in the scope of the modalities disclosed here, and such relatively small spacer heights are only limited by the desired characteristics of a finished product and possibly any prohibitive savings that may apply by employing the present. method on workpieces having relatively small sizes. The use of approximately 30 inch spacers, for example, provides the ability to prepare 30 inch side ingot cubes with fine grain size, very fine grain size, or ultrafine grain size. Ingot-sized cubic shapes of conventional alloys have been employed in forging houses for the manufacture of discs, rings, and housing parts for aeronautical or land-based turbines.
[0050] After forging of press 28 the workpiece 24 in the direction of the first orthogonal geometric axis 30, that is, in the direction A shown in figure 2 (a),
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14/54 a non-limiting embodiment of a method according to the present disclosure further comprises (step 32) allowing the temperature of the adiabatically heated inner region (not shown) of the workpiece to cool down to the workpiece forging temperature, which is shown in figure 2 (b). Cooling times of internal region, or waiting times, can vary, for example, in non-limiting modes, from 5 seconds to 120 seconds, from 10 seconds to 60 seconds, or from 5 seconds to 5 minutes. It will be recognized by a person skilled in the art that internal region cooling times required to cool the internal region to the workpiece forging temperature will be dependent on the size, shape and composition of the workpiece 24, as well as the conditions of the atmosphere surrounding workpiece 24.
[0051] During the cooling period of the internal region, an aspect of a thermal control system 33 according to non-limiting modalities disclosed here comprises heating (step 34) of an external surface region 36 of the workpiece 24 to a temperature at or near the workpiece forging temperature. In this way, the temperature of the workpiece 24 is maintained in a uniform or almost uniform and substantially isothermal condition at or near the workpiece forging temperature before each high strain rate MAF stroke. In non-limiting modalities, the use of the thermal control system 33 to heat the outer surface region 36, together with allowing the adiabatically heated inner region to cool for a specified inner region cooling time, the workpiece temperature returns to a substantially uniform temperature at or close to the workpiece forging temperature between each forging stroke abc. In another non-limiting modality according to this disclosure, the use of the thermal control system 33 to heat the outer surface region 36, together with the permission of the adiabatically heated inner region to
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15/54 to cool for a specified internal region cooling time, the workpiece temperature returns to a substantially uniform temperature in the workpiece forging temperature range between each forging stroke ab-c. for using a thermal control system 33 to heat the outer surface region of the workpiece to the workpiece forging temperature, together with allowing the adiabatically heated inner region to cool to the workpiece forging temperature, an non-limiting embodiment according to that disclosure can be referred to as "forging multiple axes with high thermally controlled strain" or for the purposes of the present invention, simply as "forging multiple axes with high strain rate".
[0052] In non-limiting modalities according to this disclosure, the phrase "external surface region" refers to a volume of approximately 50% or approximately 60% or approximately 70% or approximately 80% of the cube, in the external region of the cube.
[0053] In a non-limiting modality, the heating 34 of an external surface region 36 of the workpiece 24 can be performed using one or more external surface heating mechanisms 38 of the thermal control system 33. Examples of possible external surface heating 38 includes, but is not limited to, flame heaters for flame heating; induction heaters for induction heating; and radiant heaters for radiant heating of the workpiece 24. Other mechanisms and techniques for heating an external surface region of the workpiece will be evident to those having common knowledge after considering the present disclosure and such mechanisms and techniques are included in the scope of the present revelation. A non-limiting embodiment of an external surface region heating mechanism 38 may comprise a box oven
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16/54 (not shown). A box oven can be configured with various heating mechanisms to heat the workpiece outer surface region using one or more of the flame heating mechanisms, radiant heating mechanisms, induction heating mechanisms, and / or any other appropriate heating mechanism known now or later by a person of ordinary skill in the art.
[0054] In another non-limiting mode the temperature of the outer surface region 36 of the workpiece 24 can be heated 34 and maintained at or close to the workpiece forging temperature and in the workpiece forging temperature range using one or more matrix heaters 40 from a thermal control system 33. Matrix heaters 40 can be used to maintain forging temperature or at temperatures within the workpiece temperature forging range. In a non-limiting mode, the matrices 40 of the thermal control system are heated to a temperature comprised in a range that includes the workpiece forging temperature up to 100 ° F (55.6 ° C) below the workpiece forging temperature of work. Matrix heaters 40 may heat the matrices 42 or the die press forging surface 44 by any appropriate heating mechanism known now or later by a person skilled in the art, including, but not limited to, flame heating mechanisms, mechanisms radiant heating mechanisms, conduction heating mechanisms, and / or induction heating mechanisms. In a non-limiting embodiment, a matrix heater 40 can be a component of a box oven (not shown). Although the thermal control system 33 is shown in place and is used during the cooling balance steps 32, 52, 60 of the multi-axis forging process 26 shown in figures 2 (b), (d) and (f), it is recognized that the thermal control system 33 may or may not be in place during the forging steps
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17/54 by press 28, 46, 56 shown in figures 2 (a), (c) and (e).
[0055] As shown in figure 2 (c), one aspect of a multi-axis forging modality 26 according to this disclosure comprises press forging (step 56) the workpiece 24 at the workpiece forging temperature in the direction (C) of a third orthogonal geometric axis 58 of the workpiece 24 using a piston speed and strain rate which are sufficient to adiabatically heat the workpiece 24, or at least adiabatically an internal region of the workpiece, and plastically deform the workpiece 24. In a non-limiting embodiment, the workpiece 24 is deformed during press forging 56 to a plastic deformation of a 20% to 50% reduction in height or other dimension. In another non-limiting modality, during press forging (56) the workpiece is plastically deformed to a plastic deformation of a 30% to 40% reduction in height or other dimension. In a non-limiting mode, the workpiece 24 can be forged by press (56) in the direction of the third orthogonal geometric axis 58 up to the same spacer height used in the first stage of forging by press (28). In another non-limiting mode according to the disclosure, the internal region (not shown) of the workpiece 24 is adiabatically heated during the press forging stage (56) to the same temperatures as in the first press forging stage (28 ). In other non-limiting modalities, the high strain rates used for press forging (56) are in the same strain rate ranges as revealed for the first press forging step (28).
[0056] In a non-limiting mode, as shown by the arrow 50 in 2 (b), 2 (d) and 2 (e), the workpiece 24 can be rotated 50 on a different orthogonal geometric axis between forging steps by successive presses (eg 46, 56). As discussed above, this rotation can be referred to as
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18/54 b-c. It is understood that by using different forging configurations, it may be possible to rotate the plunger in the forge instead of rotating the workpiece 24, or a forge can be equipped with multi-axis plungers so that rotation of the workpiece is not necessary. work or forge. Obviously, the important aspect is the relative movement of the plunger and the workpiece, and that the rotation 50 of the workpiece 24 can be an optional step. In most current industrial equipment assemblies, however, rotation 50 of the workpiece on a different orthogonal geometric axis between press forging steps will be required to complete the multi-axis forging process 26.
[0057] In non-limiting modes in which abc 50 rotation is required, workpiece 24 can be rotated manually by a forge operator or by an automatic rotation system (not shown) to provide a-bc 50 rotation. automatic abc rotation can include, but is not limited to, free-oscillating fastener-style manipulator tool or the like to allow for a thermally controlled, non-limiting rate of multiple axis forging, revealed here.
[0058] After press forging 46 of the workpiece 24 in the direction of the second orthogonal geometric axis 48, that is, in the B direction, and as shown in figure 2 (d), the process 20 further comprises allowing (step 52) an adiabatically heated internal region (not shown) of the workpiece cools down to the workpiece forging temperature, which is shown in figure 2 (d). Inner region cooling times, or waiting times, can vary, for example, in non-limiting modes, from 5 seconds to 120 seconds, or from 10 seconds to 60 seconds, or 5 seconds to 5 minutes, and is known for a person skilled in the art that the minimum cooling times are dependent on the size, shape and composition of the workpiece 24, as well as characteristics of the environment surrounding the workpiece.
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19/54 [0059] During the internal region cooling time period, an aspect of a thermal control system 33 according to certain non-limiting modalities disclosed here comprises heating (step 54) an outer surface region 36 of the work 24 to a temperature at or near the workpiece forging temperature. In this way, the temperature of the workpiece 24 is maintained in a uniform or almost uniform and substantially isothermal condition at or near the workpiece forging temperature before each high strain rate MAF stroke. In non-limiting modalities, when using the thermal control system 33 to heat the outer surface region 36, together with allowing the adiabatically heated inner region to cool for a specific inner region cooling time, the temperature of the workpiece returns to a substantially uniform temperature at or close to the workpiece forging temperature between all abc forging strokes. in another non-limiting modality according to this disclosure, by using the thermal control system 33 to heat the outer surface region 36, together with allowing the adiabatically heated inner region to cool for a specified inner region cooling retention time, the workpiece temperature returns to a substantially uniform temperature in the workpiece forging temperature range before each high strain rate MAF stroke.
[0060] In a non-limiting mode, the heating 54 of an external surface region 36 of the workpiece 24 can be performed using one or more external surface heating mechanisms 38 of the thermal control system 33. Examples of control mechanisms possible heating 38 may include, but are not limited to, flame heaters for flame heating; induction heaters for induction heating; and / or radiant heaters for radially heating the workpiece 24. One mode not read
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A surface heating mechanism 38 may comprise a box oven (not shown). Other mechanisms and techniques for heating an external surface of the workpiece will be evident to those of ordinary skill after considering the present disclosure, and such mechanisms and techniques are included in the scope of the present disclosure. A box oven can be configured with various heating mechanisms to heat the external surface of the workpiece, one or more of the flame heating mechanisms, radiant heating mechanisms, radiant heating mechanisms, and / or any other known heating mechanism now or later by a person with common knowledge in the art.
[0061] In another non-limiting embodiment, the temperature of the outer surface region 36 of the workpiece 24 can be heated 54 and maintained at or close to the workpiece forging temperature and within the workpiece forging temperature range. work using one or more matrix heaters 40 from a thermal control system 33. Matrix heaters 40 can be used to keep the dies 40 or die press forging surfaces 44 of the dies at or near the part forging temperature or at temperatures within the temperature forging range. Matrix heaters 40 may heat the matrices 42 or the die press forging surface 44 by any appropriate heating mechanism known now or later by a person skilled in the art, including, but not limited to, flame heating mechanisms, mechanisms radiant heating mechanisms, conduction heating mechanisms, and / or induction heating mechanisms. In a non-limiting embodiment, a matrix heater 40 can be a component of a box oven (not shown). Although the thermal control system 33 is shown in place and is used during the cooling equilibrium steps 32, 52, 60 of the forging process
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21/54 multi-axis 26 shown in figures 2 (b), (d) and (f), it is recognized that the thermal control system 33 may or may not be in place during press forging steps 28, 46, 56 shown in figures 2 (a), (c) and (e).
[0062] As shown in figure 2 (e), an aspect of a multi-axis forging modality 26 according to this disclosure comprises press forging (step 56) the workpiece 24 at the workpiece forging temperature in the direction (C) of a third orthogonal geometric axis 58 of the workpiece 24 using a plunger speed and strain rate which are sufficient to adiabatically heat the workpiece 24 or at least adiabatically heat an internal region of the workpiece and deform plastically the workpiece 24. In a non-limiting embodiment, the workpiece 24 is formed during press forging 56 to a plastic deformation of a 20-50% reduction in height or other dimension. In another non-limiting modality, during press forging (56) the workpiece is plastically deformed to a plastic deformation of a 30% to 40% reduction in height or other dimension. In a non-limiting embodiment, the workpiece 24 can be forged by press (56) in the direction of the second orthogonal geometric axis 48 up to the same spacer height used in the first stage of press forging (28). In another non-limiting modality according to the disclosure, the internal region (not shown) of the workpiece 24 is adiabatically heated during the press forging stage (56) to the same temperatures as in the first press forging stage (28 ). In other non-limiting embodiments, the high strain rates used for press forging (56) are in the same strain rate ranges as revealed for the first press forging step (28).
[0063] In a non-limiting mode, as shown by the arrow 50 in 2 (b), 2 (d) and 2 (e), the workpiece 24 can be rotated 50 on a geometric axis
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22/54 different orthogonal between successive press forging steps (eg 46, 56). As discussed above, this rotation can be referred to as rotation ab-c. it is understood that by using different forging configurations, it may be possible to rotate the plunger in the forge instead of rotating the workpiece 24, or a forge can be equipped with multi-axis plungers so that rotation of the workpiece is not necessary work or forge. Therefore, rotation 50 of workpiece 24 can be an optional step. In most current industrial assemblies, however, rotation 50 of the workpiece to a different orthogonal geometric axis between the press forging step will be necessary to complete the multi-axis forging process 26.
[0064] After press forging 56 of the workpiece 24 in the direction of the third orthogonal geometric axis 58, that is, in the C-direction, and as shown in figure 2 (e), the process 20 further comprises allowing (step 60) that an adiabatically heated internal region (not shown) of the workpiece cools down to the workpiece forging temperature, which is shown in figure 2 (f). The cooling times of the internal region can vary, for example, from 5 seconds to 120 seconds, from 10 seconds to 60 seconds, or from 5 seconds to 5 minutes, and it is recognized by a person skilled in the art that the cooling times are dependent on the size, shape, and composition of the workpiece 24 as well as the characteristics of the environment surrounding the workpiece.
[0065] During the cooling period, an aspect of a thermal control system 33, according to non-limiting modalities disclosed here, comprises heating (step 62) an outer surface region 36 of the workpiece 24 to a temperature in or close to the workpiece forging temperature. In this way, the temperature of the workpiece 24 is maintained in a uniform or almost uniform and substantially isothermal condition at or close to the workpiece forging temperature before each rate MAF stroke.
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23/54 high deformation. In non-limiting modalities, the use of the thermal control system 33 to heat the outer surface region 36, together with allowing the adiabatically heated inner region to cool for a specified inner region cooling time, the workpiece temperature returns to a substantially uniform temperature at or close to the workpiece forging temperature between each forging stroke abc. in another non-limiting embodiment according to this disclosure, the use of thermal control system 33 to heat the outer surface region 36, together with allowing the adiabatically heated inner region to cool for a specified inner region cooling retention time, the workpiece temperature returns to a substantially isothermal condition within the workpiece forging temperature range between each abc forging stroke.
[0066] In a non-limiting mode, heating 62 of an outer surface region 36 of workpiece 24 can be performed using one or more outer surface heating mechanisms 38 of the thermal control system 33. Examples of possible heating 38 may include, but are not limited to, flame heaters for flame heating; induction heaters for induction heating; and / or radiant heaters for radiant heating of the workpiece 24. Other mechanisms and techniques for heating an external surface of the workpiece will be evident to those of ordinary skill after considering the present disclosure, and such mechanisms and techniques are included in the scope of the present revelation. A non-limiting embodiment of a surface heating mechanism 38 may comprise a box oven (not shown). A box oven can be configured with various heating mechanisms to heat the external surface of the workpiece using one or more flame heating mechanisms, radiant heating mechanisms, inward heating mechanisms
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24/54 duction and / or any other appropriate heating mechanism known now or later by a person having common knowledge in the art.
[0067] In another non-limiting embodiment, the temperature of the outer surface region 36 of the workpiece 24 can be heated 62 and maintained at or close to the workpiece forging temperature and within the workpiece forging temperature range. work using one or more matrix heaters 40 from a thermal control system 33. Matrix heaters 40 can be used to keep the dies 40 or die press forging surfaces 44 of the dies at or near the part forging temperature or at temperatures within the temperature forging range. In a non-limiting mode, the dies 40 of the thermal control system are heated to a temperature comprised in a range that includes the workpiece forging temperature at 100 ° F (55.6 ° C) below the forging temperature of the workpiece. work piece. Matrix heaters 40 can heat the matrices 42 or the die forging surface by matrix press 44 by any suitable heating mechanism known now or later by a person skilled in the art, including, but not limited to, flame heating mechanisms, radiant heating mechanisms, conduction heating mechanisms, and / or induction heating mechanisms. In a non-limiting embodiment, a matrix heater 40 can be a component of a box oven (not shown). Although the thermal control system 33 is shown in place and is used during the balancing steps, 32, 52, 60 of the multi-axis forging process shown in figures 2 (b), (d) and (f), it is recognized that the thermal control system 33 may or may not be in place during the press forging steps 28, 46, 56 shown in figures 2 (a), (c) and (e).
[0068] One aspect of the present disclosure includes a non-limiting modality
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25/54 dora in which one or more of the three stages of forging heating by orthogonal axis press, cooling and surface heating are repeated (ie, they are conducted subsequent to the end of an initial sequence of the abc, cooling forging steps internal region, and heating the external surface region) until a real deformation of at least 3.5 is obtained in the workpiece. The phrase "true deformation" is also known to a person skilled in the art as "logarithmic deformation" and also "effective deformation". With reference to figure 1, this is exemplified by step (g), that is, repeating (step 64) one or more of steps (a) - (b), (c) - (d) and (e) - (f ) until a true deformation of at least 3.5 is achieved in the workpiece. In another non-limiting modality, with reference again to figure 1, the repetition of 64 comprises repeating one or more of the steps (a) - (b), (c) - (d) and (e) - (f) until a true deformation of at least 4.7 is obtained in the workpiece. In still other non-limiting modalities, with reference again to figure 1, the repetition of 64 comprises repeating one or more of the steps (a) - (b), (c) - (d) and (e) - (f) until a true strain of 5 or more is obtained, or until a true strain of 10 is obtained on the workpiece. In another non-limiting mode, steps (a) - (f) shown in figure 1 are repeated at least 4 times.
[0069] In non-limiting multi-axis forging modes with high strain rate, thermally controlled according to the present disclosure, after a true strain of 3.7 the internal region of the workpiece comprises an alpha particle grain size average from 4 pm to 6 pm. In a thermally controlled non-limiting multi-axis forging mode, after a true deformation of 4.7 is achieved, the workpiece comprises an average grain size in a central region of the 4 pm workpiece. In a non-limiting modality according to this disclosure, when an average deformation of 3.7 or more is obtained, certain non-limiting modalities
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26/54 of the methods of the present disclosure produce grains that are equiaxial.
[0070] In a non-limiting mode of a multi-axis forging process using a thermal control system, the press-workpiece die interface is lubricated with lubricants known to those with common knowledge, as, but not limited to , graphite, glass, and / or other known solid lubricants.
[0071] In a non-limiting modality, the workpiece comprises a titanium alloy selected from the group consisting of alpha titanium alloys, alpha + beta titanium alloys, metastable beta titanium alloys, and beta titanium alloys. In another non-limiting modality, the workpiece comprises an alpha + beta titanium alloy. In yet another non-limiting modality, the workpiece comprises a metastable beta titanium alloy. Exemplary titanium alloys that can be processed using method modalities in accordance with the present disclosure include, but are not limited to: alpha + beta titanium alloys, such as Ti-6Al-4V alloy (UNS numbers R56400 and R54601 ) and Ti-6Al-2Sn-4Zr2Mo alloy (UNS numbers R54620 and R54621); quasi-beta titanium alloys such as Ti-10V-2Fe-3Al (UNS R54610)); and metastable beta titanium alloys, such as, for example, Ti-15Mo alloy (UNS R58150) and Ti-5Al-5V-5Mo-3Cr alloy (UNS not assigned). In a non-limiting modality, the workpiece comprises a titanium alloy that is selected from ASTM titanium alloys Degrees 5, 6, 12, 19, 20, 21, 23, 24, 25, 29, 32, 35, 36 and 38.
[0072] In a non-limiting mode, heating a workpiece to a workpiece forging temperature comprised in the alpha + beta phase field of the titanium or titanium alloy metallic material heats the workpiece to a beta soak temperature; retain the workpiece at the beta soak temperature for a sufficient soak period to form a 100% titanium beta phase microstructure in the workpiece; and
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27/54 cool the workpiece directly to the workpiece forging temperature. In certain non-limiting embodiments, the beta soak temperature is in a temperature range of the beta transus temperature of the titanium metal material or titanium alloy up to 300 ° F (111 ° C) above the beta transus temperature of the titanium metal material or titanium alloy. Non-limiting modalities include a beta soak time of 5 minutes to 24 hours. A person skilled in the art will understand that other beta soaking temperatures and beta soaking times are comprised in the modalities of this disclosure and, for example, that relatively large workpieces may require relatively higher beta soaking temperatures and / or beta soaking times. longer to form a 100% beta-phase titanium microstructure.
[0073] In certain non-limiting modalities in which the workpiece is retained at a beta soak temperature to form a 100% beta phase microstructure, the workpiece can also be plastically deformed at a plastic deformation temperature in the field beta phase of titanium metal material or titanium alloy before cooling the workpiece to the workpiece forging temperature. The plastic deformation of the workpiece can comprise at least one of tensile, forging by pressure, and forging multiple axes of high deformation rate of the workpiece. In a non-limiting modality, the plastic deformation in the beta phase region comprises forging the workpiece by pressure to a beta-pressure deformation in the range of 0.1 - 0.5. In non-limiting modalities, the plastic deformation temperature is in a temperature range including the beta transus temperature of the titanium metal material or titanium alloy up to 300 ° F (111 ° C) above the beta transus temperature of the titanium metal material or titanium alloy.
[0074] Figure 4 is a schematic diagram of thermomechanical temperature-temperature process for a non-limiting method of plastically deforming
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28/54 the workpiece above the beta transus temperature and directly cool to the workpiece forging temperature. In Figure 4, a non-limiting method 100 comprises heating 102 the workpiece to a beta soak temperature 104 above the beta transus temperature 106 of the titanium metal material or titanium alloy and retaining or “soaking” the workpiece in the beta 104 soaking temperature to form a microstructure of the total beta titanium phase in the workpiece. In a non-limiting embodiment according to this disclosure, after soaking 108 the workpiece can be plastically deformed 110. In a non-limiting embodiment, plastic deformation 110 comprises pressure forging to a true deformation of 0.3. In another non-limiting embodiment, the plastic deformation 110 of the workpiece comprises forging multiple axes of thermally controlled high deformation rate (not shown in Figure 4) at a beta soak temperature.
[0075] Still referring to figure 4, after plastic deformation 110 in the beta phase field, in a non-limiting mode, the workpiece is cooled 112 to a workpiece forging temperature 114 in the alpha + beta phase field metallic material of titanium or titanium alloy. In a non-limiting mode, cooling 112 comprises air cooling. After cooling 112, the workpiece is forged by multiple axes of thermally controlled high strain rate 114, according to non-limiting modalities of this disclosure. In the non-limiting mode of figure 4, the workpiece is struck or forged by a press 12 times, that is, the three orthogonal geometric axes of the workpiece are forged by a non-sequential press a total of 4 times each. In other words, with reference to figure 1, the sequence including steps (a) - (b), (c) - (d), and (e) - (f) is performed 4 times. In the non-limiting mode of figure 4, after a multiple axis forging sequence involving 12 strokes, the true deformation can equal, for example, approximately 3.7. After forging a
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29/54 multiple axes 114, the workpiece is cooled 116 to room temperature. In a non-limiting mode, cooling 116 comprises air cooling.
[0076] A non-limiting aspect of the present disclosure includes forging multiple axes of high thermally controlled strain rate at two temperatures in the alpha + beta phase field. Figure 5 is a schematic thermomechanical temperature time process diagram for a non-limiting method comprising multi-axis forging of the titanium alloy workpiece at the first workpiece forging temperature using a non-limiting aspect aspect. thermal control revealed above, followed by cooling to a second workpiece forging temperature in the alpha + beta phase, and forging multiple axes of the titanium alloy workpiece at the second workpiece forging temperature using a non-modality limiting the thermal control aspect revealed above.
[0077] In figure 5, a non-limiting method 130 comprises heating 132 the workpiece to a beta soaking temperature 134 above the beta transus 136 temperature of the alloy and retaining or soaking 138 the workpiece to the beta 134 soaking temperature for form a full beta phase microstructure in the titanium or titanium alloy workpiece. After soaking 138, the workpiece can be plastically deformed 140. In a non-limiting embodiment, plastic deformation 140 comprises pressure forging. In another non-limiting embodiment, plastic deformation 140 comprises pressure forging to a deformation of 0.3. In yet another non-limiting embodiment, the plastic deformation 140 of the workpiece comprises forging multiple axes of thermally controlled high deformation (not shown in figure 5) at a beta soak temperature.
[0078] Still with reference to figure 5, after plastic deformation 140 in the
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30/54 beta phase field, the workpiece is cooled 142 to a first workpiece forging temperature 144 in the alpha + beta phase field of the titanium metal or titanium alloy material. In a non-limiting mode, cooling 142 comprises air cooling. After cooling 142, the workpiece is forging on multiple axes of high strain rate 146 at the first workpiece forging temperature employing a thermal control system in accordance with non-limiting modalities disclosed here. In the non-limiting mode of figure 5, the workpiece is struck or forged by a press in the first times of forging temperature of workpiece 12 with 90% rotation between each stroke, that is, the three orthogonal geometric axes of the workpiece. work are forged by press 4 times each. In other words, with reference to figure 1, the sequence including steps (a) - (b), (c) - (d) and (e) - (f) is performed 4 times. In the non-limiting mode of figure 5, after forging multiple axes of high strain rate 146 the workpiece at the first workpiece forging temperature, the titanium alloy workpiece is cooled 148 to a second forging temperature workpiece 150 in the alpha + beta phase field. After cooling 148, the workpiece is forging on multiple axes of high strain rate 150 at the second workpiece forging temperature employing a thermal control system according to the non-limiting modalities disclosed here. In the non-limiting mode of figure 5, the workpiece is hit or forged by a press at the second workpiece forging temperature a total of 12 times. It is recognized that the number of strokes applied to the titanium alloy workpiece at the first and second workpiece forging temperatures can vary depending on the desired final grain size and desired true deformation, and that the number of strokes that is appropriate can be determined without undue experimentation. After forging multiple axes 150 at the second workpiece forging temperature, the
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31/54 workpiece is cooled 152 to room temperature. In a non-limiting mode, cooling 152 comprises air-cooling to room temperature.
[0079] In a non-limiting mode, the first workpiece forging temperature is in a first workpiece forging temperature range greater than 200 ° F (111.1 ° C) below the beta transus temperature of the titanium metal material or titanium alloy at 500 ° F (277.8 ° C) below the beta transus temperature of the titanium metal material or titanium alloy, that is, the first forging temperature of workpiece T1 is in the range 200 ° F> T1> Tp - 500 ° F. In a non-limiting mode, the second workpiece forging temperature is in a second workpiece forging temperature range greater than 500 ° F (277.8 ° C) below the beta transus temperature of the metal material of titanium or titanium alloy up to 700 ° F (388.9 ° C) below the beta transus temperature, ie the second workpiece forging temperature T2 is in the range of Tp - 500 ° F> T2> Tp - 700 ° F. In a non-limiting embodiment, the titanium alloy workpiece comprises Ti-6-4 alloy; the first workpiece temperature is 1500 ° F (815.6 ° C); and the second workpiece forging temperature is 1300 ° F (704.4 ° C).
[0080] Figure 6 is a schematic thermomechanical time-temperature process diagram of a non-limiting method according to the present disclosure of plastically deforming a workpiece comprising a metallic material selected from titanium and a titanium alloy above temperature beta transus and cool the workpiece down to the workpiece forging temperature, while simultaneously employing multiple axis forging of high thermally controlled strain rate on the workpiece according to non-limiting modalities of this disclosure. In figure 6, a non-limiting method 160 of using multi-axis forging of high strain rate against
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32/54 thermally refined titanium grain or titanium alloy side comprises heating 162 the workpiece to a beta soaking temperature 164 above the beta transus temperature 166 of the titanium or titanium alloy metal material and retaining or soaking 168 a workpiece at the soak temperature beta 164 to form a full beta phase microstructure in the workpiece. After soaking the workpiece 168 at temperature and soaking beta, the workpiece is plastically deformed 170. In a non-limiting embodiment, the plastic deformation 170 can comprise multi-axis forging with a high thermally controlled deformation rate. In a non-limiting embodiment, the workpiece is repeatedly forged on multiple axes of high strain rate 172 using a thermal control system as revealed here as the workpiece cools through the beta transus temperature. Figure 6 shows three intermediate, high strain rate, multi-axis forging steps 172, but it will be understood that there may be a greater or lesser number of intermediate high strain rate multi-axis forging steps 172, as desired. The intermediate high deformation rate multi-axis forging steps 172 are intermediate to the initial high deformation rate multi-axis forging step 170 at the soak temperature, and the final high deformation rate multi-axis forging step 174 of the metallic material. Although figure 6 shows a multi-axis forging step with high final strain rate in which the workpiece temperature remains fully in the alpha + beta phase field, it is understood that more than one multi-axis forging step could be carried out in the alpha + beta phase field for further grain refinement. According to non-limiting modalities of this disclosure, at least one multi-axis forging step with a high final deformation rate occurs entirely at temperatures in the alpha + beta phase field of the titanium or titanium alloy workpiece.
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33/54 [0081] Since the multi-axis forging steps 170, 172, 174 occur as the workpiece temperature cools through the beta transus temperature of the titanium or titanium alloy metal material, a method modality such as shown in figure 6 is mentioned here as “through multi-axis forging of high beta transus strain rate”. In a non-limiting modality, the thermal control system (33 of figure 2) is used by forging multiple beta transus forging to maintain the temperature of the workpiece at a uniform or substantially uniform temperature before each stroke at each working temperature. beta transus forging, and optionally, to decrease the cooling rate. After forging multiple axes 174 of the workpiece, the workpiece is cooled 176 to room temperature. In a non-limiting mode, cooling 176 comprises air cooling.
[0082] Non-limiting multi-axis forging modalities using a thermal control system, as revealed above, can be used to process titanium and titanium alloy workpieces having cross sections larger than 4 square inches using conventional forging equipment , the size of cubic workpieces can be increased to match the capabilities of an individual press. It was determined that alpha lamellae of the β-annealed structure easily break into fine uniform alpha grains at workpiece forging temperatures revealed in non-limiting modalities here. It has also been determined that decreasing the workpiece forging temperature decreases the alpha particle size (grain size).
[0083] Although not wishing to be linked to any specific theory, it is believed that the grain refinement that occurs in non-limiting modalities of forging multiple axes of high deformation rate, thermally controlled according to this revelation occurs through meta recrystallization -dynamics. In the process of forging multiple axes of slow deformation rate of the technique
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34/54 above, dynamic recrystallization occurs instantly during the application of deformation to the material. It is believed that in forging multiple axes with high strain rate according to this relationship, meta-dynamic recrystallization occurs at the end of each strain or forging stroke, while at least the internal region of the workpiece is hot from the adiabatic heating. Residual adiabatic heat, cooling times of the inner region, and heating of the outer surface region influence the extent of grain refinement in non-limiting multi-axis forging methods of high strain rate, thermally controlled according to this disclosure.
[0084] Forging multiple axes using a thermal control system and cube-shaped work pieces comprising a metallic material selected from titanium and titanium alloys, as revealed above, has been observed to produce certain results less than optimal. It is believed that one or more of (1) the cubic workpiece geometry used in certain thermally controlled multi-axis forging modalities disclosed here, (2) die cooling (that is, letting the die temperature dip significantly below of the workpiece forging temperature), and (3) the use of high strain rates concentrates strain in the core region of the workpiece.
[0085] One aspect of the present disclosure comprises forging methods that can obtain generally uniform fine grain, very fine grain or ultrafine grain size in ingot-sized titanium alloys. In other words, a workpiece processed by such methods can include the desired grain size, such as ultra-fine grain microstructure throughout the workpiece, rather than just in a central region of the workpiece. Non-limiting modalities of such methods use “multiple pressure and traction” steps in ingots having cross sections larger than 4 square inches. The multiple pressure and traction steps are aimed at obtaining uniform fine grain, very fine grain or ta
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35/54 ultra-fine grain hand throughout the workpiece, while substantially preserving the original dimensions of the workpiece. Since these forging methods include multiple pressure and pull stages, they are mentioned here as modalities of the “MUD” method. The MUD method includes severe plastic deformation and can produce uniform ultrafine grains in ingot-sized titanium alloy workpieces. In non-limiting modalities according to this disclosure, strain rates used for the pressure forging and stretching forging stages of the MUD process are in the range of 0.001 s ^-1 to 0.02 s ^-1 , inclusive. On the contrary, strain rates typically used for conventional open die forging and compressing are in the range of 0.03 s ^-1 to 0.1 s ^-1 . The deformation rate for MUD is slow enough to avoid adiabatic heating to keep the forging temperature in control, yet the deformation rate is acceptable for commercial practices.
[0086] A schematic representation of non-limiting modalities of multiple pressure and traction, that is, the “MUD” method is provided in figure 7, and a flow chart of certain modalities of the MUD method is provided in figure 8. With reference to figures 7 and 8, a non-limiting method 200 for refining grains in a workpiece comprising a selected titanium metal material and a titanium alloy using multiple stretch and pressure forging steps comprises heating 202 a workpiece of titanium alloy metal material or cylinder-like titanium up to a workpiece forging temperature in the alpha + beta phase field of the metal material. In a non-limiting mode, the cylinder-like workpiece shape is a cylinder. In another non-limiting mode, the shape of the cylinder-like workpiece is an octagonal cylinder or a straight octagon.
[0087] The cylinder-like workpiece has a starting cross-section dimension. In a non-limiting modality of the MUD method of
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36/54 according to the present disclosure in which the starting workpiece is a cylinder, the dimension in starting cross-section is the diameter of the cylinder. In a non-limiting modality of the MUD method according to the present disclosure in which the starting workpiece is an octagonal cylinder, the dimension in starting cross section is the diameter of the circumscribed circle of the octagonal cross section, that is, the diameter of the circle that passes through all the vertices of the octagonal cross section.
[0088] When the cylinder-like workpiece is at the workpiece forging temperature, the workpiece is pressure forged 204. After pressure forging 204, in a non-limiting mode, the workpiece is rotated ( 206) 90 ° and then subjected to multi-pass forging stretch 208. Effective rotation 206 of the workpiece is optional, and the purpose of the step is to arrange the workpiece in the correct orientation (see figure 7) with respect to to a forging device for subsequent multi-pass drawing forging steps 208.
[0089] Multi-pass drawing forging comprises incrementally rotating (represented by the arrow 210) the workpiece in a rotational direction (indicated by the arrow direction 210), followed by stretching forging 212 of the workpiece after each increment of rotation . In non-limiting modes, rotating incrementally and forging by traction are repeated 214 until the workpiece understands the dimension in starting cross-section. In a non-limiting mode, the pressure forging and multiple-pass forging steps are repeated until a true deformation of at least 3.5 is achieved in the workpiece. Another non-limiting modality involves repeating the heating, pressure forging and multiple pass stretching forging steps until a true deformation of at least 4.7 is achieved in the workpiece. In yet another non-limited modality
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37/54 ra, the steps of heating, pressure forging and multiple pass drawing forging are repeated until a true deformation of at least 10 is achieved in the workpiece. It is observed in non-limiting modalities that when a true deformation of 10 transmitted to the MUD forging, an alpha UFG microstructure is produced, and that the increase in the true deformation transmitted to the workpiece results results in smaller average grain sizes.
[0090] One aspect of this disclosure is to employ a deformation rate during the pressure and multiple traction steps that is sufficient to result in severe plastic deformation of the titanium alloy workpiece, which, in non-limiting modalities, additionally results in size of ultrafine grain. In a non-limiting modality, a strain rate used in pressure forging is in the range of 0.001 s ^-1 to 0.003 s ^-1 . In another non-limiting modality, a strain rate used in the multiple stretch forging steps is in the range of 0.01 s ^-1 to 0.02 s ^-1 . It is determined that the deformation rates in these ranges do not result in adiabatic heating of the workpiece, which allows the workpiece temperature control, and are sufficient for an economically acceptable commercial practice.
[0091] In a non-limiting mode, after completing the MUD method, the workpiece has substantially the original dimensions of the starting cylinder 214 or octagonal cylinder 216. In yet another non-limiting mode, after completing the MUD method, the workpiece The workpiece has substantially the same cross section as the starting workpiece. In a non-limiting mode, a single pressure requires many strokes to return the workpiece to a shape including the starting cross section of the workpiece.
[0092] In a non-limiting mode of the MUD method in which the workpiece is in the shape of a cylinder, rotate incrementally and forge by
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38/54 traction additionally comprises multiple steps of rotating the cylindrical workpiece in 15 ° increments and subsequently forging by traction, until the cylindrical workpiece is rotated through 360 ° C and is forged by traction in each increment. In a non-limiting modality of the MUD method in which the workpiece is in the shape of a cylinder, after each pressure forging, twenty-four stretching forging steps + incremental rotation are used to bring the workpiece substantially to its dimension in cross-section starting. In another non-limiting mode, when the workpiece is in the shape of an octagonal cylinder, rotating incrementally and forging by traction further comprises multiple steps of rotating the cylindrical workpiece in 45 ° increments and subsequently forging by traction, up to that the cylindrical workpiece is rotated through 360 ° and is forged by traction in each increment. In a non-limiting modality of the MUD method in which the workpiece is in the shape of an octagonal cylinder, after each pressure forging, eight steps of stretching forging + incremental rotation are employed to bring the workpiece substantially to its dimension in starting cross section. It was observed in non-limiting modalities of the MUD method that the manipulation of an octagonal cylinder by manipulation equipment was more accurate than the manipulation of a cylinder by manipulation equipment. It was also observed that the manipulation of an octagonal cylinder by manipulation equipment in a non-limiting modality of a MUD was more accurate than the manipulation of a cubic workpiece using hand tongs in non-limiting modalities of the high strain rate MAF process thermally controlled revealed here. It is recognized that other quantities of forging steps by drawing and incremental rotation for cylinder-like ingots are included in the scope of this disclosure, and such other possible amounts of incremental rotation can be determined by a
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39/54 person versed in the technique without undue experimentation.
[0093] In a non-limiting MUD mode according to this disclosure, a workpiece forging temperature comprises a temperature in a workpiece forging temperature range. In a non-limiting mode, the workpiece forging temperature is in a workpiece forging temperature range of 100 ° F (55.6 ° C) below the beta transus (Tb) temperature of the alloy metal material titanium or titanium at 700 ° F (388.9 ° C) below the beta transus temperature of the titanium or titanium alloy metal material. In yet another non-limiting mode, the workpiece forging temperature is in a temperature range of 300 ° F (166.7 ° C) below the beta transition temperature of the titanium metal material or titanium alloy at 625 ° F (347 ° C) below the beta transition temperature of the titanium metal material or titanium alloy. In a non-limiting embodiment, the low end of a workpiece forging temperature range is a temperature in the alpha + beta phase field at which substantial damage does not occur on the workpiece surface during the forging stroke, as can be be determined without undue experimentation by a person having common knowledge in the art.
[0094] In a non-limiting MUD according to the present disclosure, the workpiece forging temperature range for a Ti-6-4 alloy (Ti-6Al-4V; UNS no. R56400), which has a beta transus temperature (Tb) of approximately 1850 ° F (1010 ° C) can be, for example, from 1150 ° F (621.1 ° C) to 1750 ° F (954.4 ° C) or in another mode it can be from 1225 ° F (662.8 ° C) to 1550 ° F (843.3 ° C).
[0095] Non-limiting modalities comprise multiple reheating steps during the MUD method. In a non-limiting mode, the titanium alloy workpiece is heated to the forging temperature of
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40/54 work after pressure forging the titanium alloy workpiece. In another non-limiting modality, the titanium alloy workpiece is heated to the workpiece forging temperature before the multi-pass forging stretch forging step. In another non-limiting embodiment, the workpiece is heated as necessary to bring the effective workpiece temperature back to the workpiece forging temperature after a pressure or tensile forging step.
[0096] It was determined that modalities of the MUD method transmit redundant work or extreme deformation, also referred to as severe plastic deformation, which is aimed at creating ultrafine grains in a work piece comprising a metallic material selected from titanium and titanium alloy. Without wishing to be limited by any specific operating theory, it is believed that the octagonal or round cross-sectional shape of octagonal and cylindrical workpieces, respectively, distributes deformation more evenly across the cross-sectional area of the workpiece over a MUD method. The detrimental effect of friction between the workpiece and the forging die is also reduced by reducing the area of the workpiece in contact with the die.
[0097] In addition, it was also determined that decreasing the temperature during the MUD method reduces the final grain size to a size that is characteristic of the specific temperature being used. With reference to figure 8, in a non-limiting mode of a method 200 to refine the grain size of a workpiece, after processing by the MUD method at the workpiece forging temperature, the workpiece temperature can be cooled 216 to a second workpiece forging temperature. After cooling the workpiece to the second workpiece forging temperature, in a non-limiting mode, the workpiece is forged by pressure at the second workpiece forging temperature 218. The workpiece is
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41/54 rotated 220 or oriented for subsequent stretching forging steps. The workpiece is forged by multi-step pulling at the second workpiece forging temperature 222. The multi-step stretching forging at the second workpiece forging temperature 222 comprises incrementally rotating the workpiece 224 by a rotational direction (see figure 7), and forging by traction at the second temperature of forging workpiece 226 after each increment of rotation. In a non-limiting mode, the steps of forging by pressure, rotating incrementally 224, and forging by traction are repeated 226 until the workpiece comprehends the starting cross-section dimension. In another non-limiting embodiment, the pressure forging steps at the second workpiece temperature 218, rotation 220, and multi-step stretching forging 222 are repeated until a true deformation of 10 or greater is achieved in the workpiece. It is recognized that the MUD process can continue until any desired true deformation is transmitted to the titanium or titanium alloy workpiece.
[0098] In a non-limiting mode comprising multiple temperature MUD method, the workpiece forging temperature, or a first workpiece forging temperature, is approximately 1600 ° F (871.1 ° C) and the second workpiece forging temperature is approximately 1500 ° F (815.6 ° C). Subsequent workpiece forging temperatures that are lower than the first and second workpiece forging temperatures, such as a third workpiece forging temperature, a fourth workpiece forging temperature, and so on , are included in the scope of non-limiting modalities of this disclosure.
[0099] As forging proceeds, grain refinement results in decreasing flow deformation at a fixed temperature. It was determined that the
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42/54 decreasing the forging temperature for sequential pressure and traction steps keeps flow deformation constant and increases the rate of microstructural refinement. It was determined that in non-limiting MUD modalities according to this disclosure, a true deformation of 10 results in a uniform ultra-fine alpha-grain microstructure of uniform titanium and titanium alloy workpieces, and that the lowest temperature of a process Two-temperature (or multi-temperature) MUD can be determinative of the final grain size after a true deformation of 10 is transmitted to the MUD forging.
[00100] One aspect of this disclosure includes that after processing by the MUD method, subsequent deformation steps are possible without thickening the refined grain size, as long as the workpiece temperature is not subsequently heated above the beta transus temperature of the titanium alloy . For example, in a non-limiting modality, a subsequent deformation practice after MUD processing may include stretch forging, multiple stretch forging, pressure forging, or any combination of two or more of these forging steps at temperatures in the alpha phase field + titanium beta or titanium alloy. In a non-limiting embodiment, subsequent forging or deformation steps include a combination of multi-pass stretch forging, pressure forging, and stretch forging to reduce the starting cross-section dimension of the cylinder-like workpiece to a fraction of the dimension in cross section, for example, but not limited to, half of the dimension in cross section, a quarter of the dimension in cross section, and so on, while still maintaining a uniform fine grain, very fine grain or structure of ultra-fine grain in the titanium or titanium alloy workpiece.
[00101] In a non-limiting mode of a MUD method, the workpiece comprises a titanium alloy selected from the group consisting of a
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43/54 alpha titanium alloy, an alpha + beta titanium alloy, a metastable beta titanium alloy, and a beta titanium alloy. In another non-limiting modality of a MUD method, the workpiece comprises an alpha + beta titanium alloy. In yet another non-limiting mode of the multiple pressure and traction process disclosed here, the workpiece comprises a metastable beta titanium alloy. In a non-limiting modality of a MUD method, the workpiece is a titanium alloy selected from ASTM titanium alloys Degrees 5, 6, 12, 19, 20, 21, 23, 24, 25, 29, 32, 35, 36 and 38.
[00102] Before heating the workpiece to the forging temperature of the workpiece in the alpha + beta phase field according to the MUD modalities of this disclosure, in a non-limiting mode the workpiece can be heated to a temperature of beta soak, retained at the beta soak time for sufficient beta soak time to form a 100% beta-phase titanium microstructure in the workpiece, and cooled to room temperature. In a non-limiting mode, the beta soak temperature is in a beta soak temperature range that includes the beta transus temperature of the titanium or titanium alloy up to 300 ° F (111 ° C) above the beta transus temperature of the titanium or alloy of titanium. In another non-limiting modality, the time to soak beta is 5 minutes to 24 hours.
[00103] In a non-limiting mode, the workpiece is an ingot that is coated on all or certain surfaces with a lubricant coating that reduces friction between the workpiece and the forging dies. In a non-limiting modality, the lubricant coating is a solid lubricant such as, but not limited to, one of graphite and a glass lubricant. Other lubricant coatings known now or later by a person of ordinary skill in the art are within the scope of the present disclosure. In addition, in a non-limiting mode of the MUD method using workpiecesPetition 870190018714, of 25/02/2019, p. 60/96
44/54
Similar to a cylinder, the contact area between the workpiece and the forging dies is small in relation to the contact area in multi-axis forging of a cubic workpiece. The reduced contact area results in reduced matrix friction and a more uniform titanium alloy workpiece microstructure and macrostructure.
[00104] Before heating the workpiece comprising a metallic material selected from titanium and titanium alloys at the temperature of forging the workpiece in the alpha + beta phase field according to the MUD modalities of this disclosure, in a non-limiting modality, the workpiece is plastically deformed at a plastic deformation temperature in the beta phase field of the titanium or titanium alloy metal material after being retained in sufficient beta soak time to form 100% beta phase in the titanium or titanium alloy and before cooling to room temperature. In a non-limiting mode, the plastic deformation temperature is equivalent to the beta soak temperature. In another non-limiting embodiment, the plastic deformation temperature is in a plastic deformation temperature range that includes the beta transus temperature of titanium or titanium alloy up to 300 ° F (111 ° C) above the beta transus temperature of titanium or titanium alloy.
[00105] In a non-limiting embodiment, plastically deforming the beta phase field of titanium or titanium alloy comprises at least one stretching, pressure forging and multi-axis forging of high deformation rate of the titanium alloy workpiece . In another non-limiting modality, plastically deforming the workpiece in the beta phase field of titanium or titanium alloy comprises forging by stretching and multiple pressure according to non-limiting modalities of this disclosure, and in which the cooling of the workpiece to the Workpiece forging temperature comprises air cooling. In yet another non-limiting modality, plastically deform the
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45/54 workpiece in the beta phase field of titanium or titanium alloy comprises pressure forging of the workpiece up to a 30-35% reduction in height or other dimension, such as length.
[00106] Another aspect of the present disclosure may include heating the forging dies during forging. A non-limiting modality comprises heating dies from a forge used to forge the workpiece to a temperature in a temperature range limited by the workpiece forging temperature to 100 ° F (55.6 ° C) below the forging temperature of workpiece, inclusive.
[00107] It is believed that certain methods disclosed here can also be applied to metals and metal alloys other than titanium and titanium alloys to reduce the grain size of the workpieces of these alloys. Another aspect of this disclosure includes non-limiting modalities of a method for forging multi-layers with a high deformation rate of metals and metal alloys. A non-limiting embodiment of the method comprises heating a workpiece comprising a metal or metal alloy to a workpiece forging temperature. After heating, the workpiece is forged at the workpiece forging temperature at a deformation rate sufficient to adiabatically heat an internal region of the workpiece. After forging, a waiting period is employed before the next forging step. During the waiting period, the temperature of the adiabatically heated inner region of the metal alloy workpiece is allowed to cool down to the workpiece forging temperature, while at least one surface region of the workpiece is heated to the temperature forging workpiece. The steps of forging the workpiece and then let the adiabatically heated inner region of the workpiece equilibrate to the workpiece forging temperature while heating at least one surface region of the metal alloy workpiece
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46/54 until the workpiece forging temperature is repeated until a desired characteristic is obtained. In a non-limiting mode, forging comprises one or more press forging, pressure forging, stretching forging and roller forging. In another non-limiting modality, the metal alloy is selected from the group consisting of titanium, zirconium and zirconium alloys, aluminum alloys, ferrous alloys and superalloys. In yet another non-limiting modality, the desired characteristic is one or more of a transmitted deformation, an average grain size, a shape and a mechanical property. Mechanical properties include, but are not limited to, strength, ductility, fracture toughness and hardness.
[00108] Following are several examples that illustrate certain non-limiting modalities in accordance with the present disclosure.
EXAMPLE 1 [00109] Forging multiple axes using a thermal control system was performed on a titanium alloy workpiece consisting of Ti-
6-4 having equiaxial alpha grains with grain sizes in the range of 10-30 pm. A thermal control system was employed that included heated dies and flame heating to heat the surface region of the titanium alloy workpiece. The workpiece consisted of a cube with a 4 inch side. The workpiece was heated in a gas powered box oven to a beta annealing temperature of 1940 ° F (1060 ° C), that is, approximately 50 ° F (27.8 ° C) above the beta transus temperature. The beta annealing soaking time was 1 hour. The beta annealed workpiece was air cooled to room temperature, ie, approximately 70 ° F (21.1 ° C).
[00110] The beta annealed workpiece was then heated in a gas powered box oven to the workpiece forging temperature of 1500 ° F (815.6 ° C), which is in the alpha + beta phase field of the league. The workpiece
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The annealed beta 47/54 was first forged by press in the direction of the geometric axis A of the workpiece up to a spacer height of 3.25 inches. The plunger speed of the press forging was 1 inch / second, which corresponded to a deformation rate of 0.27 s ^-1 . The adiabatically heated center of the workpiece and the flame-heated surface region of the workpiece were left to equilibrate to the workpiece forging temperature for approximately 4.8 minutes. The workpiece was rotated and press-forged in the direction of the workpiece's geometric axis B to a spacer height of 3.25 inches. The plunger speed of the press forging was 1 inch / second, which corresponded to a deformation rate of 0.27 s ^-1 . The adiabatically heated center of the workpiece and the flame-heated surface region of the workpiece were left to equilibrate to the workpiece forging temperature for approximately 4.8 minutes. The workpiece was rotated and press-forged in the direction of the workpiece's geometric axis C to a spacer height of 4 inches. The plunger speed of the press forging was 1 inch / second, which corresponded to a deformation rate of 0.27 s ^-1 . The adiabatically heated center of the workpiece and the flame-heated surface region of the workpiece were left to equilibrate to the workpiece forging temperature for approximately 4.8 minutes. The abc forging (multiple axes) described above was repeated four times for a total of 12 forging strokes, producing a true deformation of 4.7. After forging multiple axes, the workpiece was abruptly cooled with water. The thermomechanical processing path for example 1 is shown in figure 9.
EXAMPLE 2 [00111] A sample of the starting material in example 1 and a sample of the material as processed in example 1 were metallographically prepared and the
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48/54 grain structures were microscopically observed. Figure 10 is a micrograph of the beta annealed material of example 1 showing equiaxial grains with grain sizes between 10-30 pm. Figure 11 is a micrograph of a central region of the forged sample a-b-c in Example 1. The grain structure in Figure 11 has equiaxial grain sizes of the order of 4 µm and would qualify as “very fine grain” (VFG) material. In the sample, the grains of size VFG were observed predominantly in the center of the sample. Grain sizes in the sample were larger as the distance from the center of the sample increased.
EXAMPLE 3 [00112] Finite element modeling was used to determine internal region cooling times required to cool the adiabatically heated internal region to a workpiece forging temperature. In modeling, an alpha-beta titanium alloy preform 5 inches in diameter by 7 inches long was virtually heated to a multi-axis forging temperature of 1500 ° F (815.6 ° C). The forging dies were simulated to be heated to 600 ° F (315.6 ° C). A plunger speed was simulated at 1 inch / second, which corresponds to a strain rate of 0.27 s ^-1 . Different intervals for the internal region cooling times were entered to determine an internal region cooling time required to cool the simulated workpiece adiabatically heated internal region to the workpiece forging temperature. From the graph in Figure 10, it is seen that the modeling suggests that tender region cooling times between 30 and 45 seconds could be used to cool the adiabatically heated inner region to a workpiece forging temperature of approximately 1500 ° F (815.6 ° C).
EXAMPLE 4 [00113] Multi-axis forging of high strain rate used
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49/54 using a thermal control system was performed on a titanium alloy workpiece consisting of a cube with a 4 inch (10.16 cm) side of Ti-6- alloy
4. The titanium alloy workpiece was beta annealed at 1940 ° F (1060 ° C) for 60 minutes. after beta annealing, the workpiece was air-cooled to room temperature. The titanium alloy workpiece has been heated to a 1500 ° F (815.6 ° C) workpiece forging temperature which is in the alpha-beta phase field of the titanium alloy workpiece. The workpiece was forged with multiple axes using a thermal control system comprising gas flame heaters and heated matrices in accordance with non-limiting modalities of this disclosure to balance the temperature of the outer surface region of the workpiece to the forging temperature workpiece between multiple axis forging strokes. The workpiece was forged by a 3.2 inch (8.13 cm) press. Using rotation a-b-c, the workpiece was substantially forged by press at each stroke up to 4 inches (10.16 cm). A plunger speed of 1 inch per second (2.54 cm / s) was used in the press forging stages, and a pause, that is, an internal region cooling time or 15 seconds equilibration time, was used between press forging blows. The equilibrium time is the time that is allowed for the adiabatically heated inner region to cool to the workpiece forging temperature while heating the outer surface region to the workpiece forging temperature. A total of 12 strokes were used at the workpiece temperature of 1500 ° F (815.6 ° C), with a 90 ° rotation of the cubic workpiece between strokes, that is, the cubic workpiece was forged abc four times.
[00114] The workpiece temperature was then lowered to a second workpiece forging temperature of 1300 ° F (704.4 ° C). The titanium alloy workpiece was forged on multiple axes of high deformation
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50/54 according to non-limiting modalities of this disclosure, using a plunger speed of 1 inch per second (2.54 cm / s) and cooling times of internal region of 15 seconds between each forging stroke. The same thermal control system used to control the first workpiece forging temperature was used to control the second workpiece forging temperature. A total of 6 forging strokes were applied at the second workpiece forging temperature, that is, the cubic workpiece was forged a-b-c twice at the second workpiece forging temperature.
EXAMPLE 5 [00115] A micrograph of the cube center after processing as described in example 4 is shown in figure 13. From figure 13, it is observed that the grains in the center of the cube have an average grain size equiaxial less than 3 pm, that is, an ultrafine grain size.
[00116] Although the center or inner region of the cube processed according to example 4 had an ultrafine grain size, it was also observed that the grains in regions of the processed cube external to the central region were not ultrafine grains. This is evident from figure 14 which is a photograph of a cross section of the cube processed according to example 4.
EXAMPLE 6 [00117] Thin element modeling was used to simulate deformation in forged multi-axis forging of a hub. The simulation was performed for a cube with a 4-inch side of Ti-6-4 alloy that was annealed beta at 1940 ° F (1060 ° C) until a full beta microstructure is obtained. The simulation used isothermal multi-axis forging, as used in certain non-limiting modalities of a method disclosed here, conducted at 1500 ° F (815.6 ° C). The workpiece was forged by a-b-c press with twelve total strokes, that is, four sets of rotations / forgings with orthogonal geometric axis a-b-c. in the simulation,
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51/54 the cube was cooled to 1300 ° F (704.4 ° C) and forged by press at a high deformation rate for 6 strokes, that is, two sets of rotations / forgings of orthogonal geometric axis a-b-c. the simulated plunger speed was 1 inch per second (2.54 cm / s). The results shown in figure 15 predict levels of deformation in the cube after processing as described above. The finite element modeling simulation predicts a maximum deformation of 16.8 in the center of the cube. The highest deformation, however, is very localized, and most of the cross section does not obtain a deformation greater than 10.
EXAMPLE 7 [00118] A workpiece comprising Ti-6-4 alloy in the configuration of a five-inch diameter cylinder that is 7 inches high (that is, measured along the longitudinal axis) was annealed beta at 1940 ° F (1060 ° C) for 60 minutes. The beta annealed cylinder was abruptly cooled with air to preserve the total beta microstructure. The beta-annealed cylinder was heated to a workpiece forging temperature of 1500 ° F (815.6 ° C) and was followed by tensile and multiple pressure forging according to non-limiting modalities of this disclosure. The multiple pressure and pull sequence included pressure forging at a height of 5.25 inches (ie reduced in size along the longitudinal geometry axis), and multiple traction forging including 45 ° incremental rotations around the geometry axis longitudinal and stretch forging to form an octagonal cylinder having a circumscribed starting and finishing circle diameter of 4.75 inches. A total of 36 forges per stretch with incremental rotations were used, with no waiting times between strokes.
EXAMPLE 8 [00119] A micrograph of a central region of a cross section of the sample prepared in example 7 is shown in figure 16 (a). A micrograph of
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52/54 region close to the surface of a cross section of the sample prepared in example 7 is shown in figure 16 (b). Examination of figures 16 (a) and (b) reveals that the sample processed according to example 7 obtained a uniform and equiaxial grain structure having an average grain size of less than 3 µm, which is classified as very fine grain (VFG).
EXAMPLE 9 [00120] A workpiece comprising Ti-6-4 alloy configured as a cylindrical ingot ten inches in diameter having a length of 24 inches was coated with silica glass paste lubricant. The ingot was annealed beta at 1940 ° C. The beta annealed ingot was forged by 24 inch pressure to a length reduction of 30-35%. After beta pressure, the ingot was subjected to forging by multiple pass stretching, which comprised spinning incrementally and forging by traction the ingot to a ten inch octagonal cylinder. The beta processed octagonal cylinder was air-cooled to room temperature. For the multiple pressure and traction process, the octagonal cylinder was heated to a first workpiece forging temperature of 1600 ° F (871.1 ° C). The octagonal cylinder was forged by pressure to a reduction of 2030% in length, and then forged by multiple traction, which included rotating the workpiece in 45 ° increments followed by stretching forging, until the octagonal cylinder obtained its dimension in starting cross section. Pressure forging and multi-pass stretch forging at the first workpiece forging temperature was repeated three times, and the workpiece was reheated as needed to bring the workpiece temperature back to the workpiece forging temperature of work. The workpiece was cooled to a second workpiece forging temperature of 1500 ° F (815.6 ° C). The stretch and multiple pressure forging procedure used at the first workpiece forging temperature was repeated at
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53/54 second workpiece forging temperature. A schematic thermomechanical temperature graph for the sequence of steps in this example 9 is shown in figure 17.
[00121] The workpiece was forged by multi-pass traction at a temperature in the alpha + beta phase field using conventional forging parameters and cut in half for pressure. The workpiece was forged by pressure at a temperature in the alpha + beta phase field using conventional forging parameters at a 20% reduction in length. In a finishing step, the workpiece was forged by traction to a round cylinder 5 inches in diameter with a length of 36 inches.
EXAMPLE 10 [00122] A macro photograph of a cross section of a sample processed according to the non-limiting modality of example 9 is shown in figure 18. It is seen that a uniform grain size is present throughout the ingot. A micrograph of the sample processed according to the non-limiting modality of example 9 is shown in figure 19. The micrograph demonstrates that the grain size is in the very fine grain size range.
EXAMPLE 11 [00123] Finite element modeling was used to simulate deformation of the sample prepared in example 9. The finite element model is shown in figure 20. The finite element model provides relatively uniform effective deformation greater than 10 for the most part of the 5-inch round ingot.
[00124] It will be understood that the present description illustrates those aspects of the invention relevant to a clear understanding of the invention. Certain aspects that would be evident to those of ordinary skill in the art and therefore would not facilitate a better understanding of the invention have not been presented to simplify the present description. Although only a limited number of mo
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54/54 dalities of the present invention is necessarily described here, a person of ordinary skill in the art, after considering the above description, will recognize that many modifications and variations of the invention can be employed. All such variations and modifications of the invention are intended to be covered by the above description and the following claims.

权利要求:
Claims (7)
[1]
1. Method of refining a grain size of a workpiece comprising a metallic material selected from titanium and a titanium alloy, the method CHARACTERIZED by the fact that it comprises:
heat the workpiece to a workpiece forging temperature in an alpha + beta phase field of the metal material, where the workpiece forging temperature is in a temperature range of 55.6 ° C below beta transus temperature (Tb) of the metallic material at 388.9 ° C below the beta transus temperature of the metallic material; and forging the workpiece in multiple axes, where forging multiple axes comprises:
press forging the workpiece at the workpiece forging temperature in the direction of a first orthogonal geometric axis of the workpiece with a strain rate in the range of 0.2 s ^-1 to 0.8 s ^-1 and that is sufficient to adiabatically heat an inner workpiece region, allow the adiabatically heated inner region of the workpiece to cool down to the workpiece forging temperature, while heating an outer surface region of the workpiece to the temperature of workpiece forging, press forging the workpiece at the workpiece forging temperature in the direction of a second orthogonal geometric axis of the workpiece with a strain rate in the range of 0.2 s ^-1 to 0, 8 s ^-1 and that is sufficient to adiabatically heat the internal region of the workpiece, allow the adiabatically heated internal region of the workpiece to cool to temperature of workpiece forging, while heating an outer surface region of the workpiece to the workpiece forging temperature,
Petition 870190061436, of 07/01/2019, p. 9/12
[2]
2/4 press forging the workpiece at the workpiece forging temperature in the direction of a third orthogonal geometric axis of the workpiece with a strain rate in the range of 0.2 s-1 to 0.8 s- 1 and which is sufficient to adiabatically heat the workpiece's inner region, allow the adiabatically heated inner region of the workpiece to cool down to the workpiece forging temperature, while heating an outer surface region of the workpiece to the workpiece forging temperature, and repeat at least one of the press forging steps and previous steps until a true deformation of at least 3.5 is achieved in at least one region of the workpiece.
2. Method, according to claim 1, CHARACTERIZED by the fact that heating a workpiece to a workpiece forging temperature within an alpha + beta phase field of the metallic material comprises:
heat the workpiece to a beta soak temperature of the metal material;
retain the workpiece at the beta soak temperature for a beta soak time of 5 minutes to 24 hours and which is sufficient to form a 100% beta phase microstructure in the workpiece; and cool the workpiece to the workpiece forging temperature.
[3]
3. Method, according to claim 2, CHARACTERIZED by the fact that it also comprises plastically deforming the workpiece at a plastic deformation temperature of the beta transus temperature of the metallic material up to 300 ° F (111 ° C) above the beta temperature transus of the metallic material in the beta phase field of the metallic material before cooling the workpiece to the workpiece forging temperature.
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3/4
[4]
4. Method, according to claim 3, CHARACTERIZED by the fact that plastically deforming the workpiece comprises forging by pressure of the workpiece up to a beta pressure deformation in the range of 0.1 to 0.5, inclusive.
[5]
5. Method, according to claim 1, CHARACTERIZED by the fact that the adiabatically heated internal region of the workpiece is allowed to cool for an internal region cooling time in the range of 5 seconds up to and including 120 seconds.
[6]
6. Method, according to claim 1, CHARACTERIZED by the fact that it also comprises heating a forging die used to forge the workpiece by press to a temperature in a temperature range of the forging temperature of the workpiece. working up to 100 ° F (55.6 ° C) below the workpiece forging temperature, inclusive.
[7]
7. Method, according to claim 1, CHARACTERIZED by the fact that it also comprises:
cooling the workpiece to a second workpiece forging temperature in the alpha + beta phase field of the metal material;
press forging the workpiece at the second workpiece forging temperature in the direction of a first orthogonal geometric axis of the workpiece with a deformation rate sufficient to adiabatically heat the internal region of the workpiece;
allowing the adiabatically heated inner region of the workpiece to cool to the second workpiece forging temperature, while heating the outer surface region of the workpiece to the second workpiece forging temperature;
press forging the workpiece at the second workpiece forging temperature in the direction of a second orthogonal geometric axis with a
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4/4 deformation rate that is sufficient to adiabatically heat the internal region of the workpiece;
allowing the adiabatically heated inner region of the workpiece to cool to the second temperature of forging the workpiece, while heating the outer surface region of the workpiece to the second temperature of forging the workpiece;
press forging the workpiece at the second temperature of forging the workpiece in the direction of a third orthogonal geometric axis of the workpiece with a deformation rate that is sufficient to adiabatically heat the internal region of the workpiece;
allowing the adiabatically heated inner region of the workpiece to cool to the second temperature of forging the workpiece, while heating an outer surface region of the workpiece to the second temperature of forging the workpiece; and repeating one or more of the previous forging and press forging steps until a true deformation of at least 10 is achieved in at least one region of the workpiece.

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BR112013005795B1|2019-12-17|method of refining a grain size of a workpiece comprising a selected titanium metal material and a titanium alloy

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法律状态:
2017-05-23| B25D| Requested change of name of applicant approved|Owner name: ATI PROPERTIES LLC (US) |

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2018-11-27| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2019-04-02| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2019-11-12| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2019-12-17| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 22/08/2011, OBSERVADAS AS CONDICOES LEGAIS. |

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2021-06-22| B21F| Lapse acc. art. 78, item iv - on non-payment of the annual fees in time|Free format text: REFERENTE A 10A ANUIDADE. |

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2021-10-13| B24J| Lapse because of non-payment of annual fees (definitively: art 78 iv lpi, resolution 113/2013 art. 12)|Free format text: EM VIRTUDE DA EXTINCAO PUBLICADA NA RPI 2633 DE 22-06-2021 E CONSIDERANDO AUSENCIA DE MANIFESTACAO DENTRO DOS PRAZOS LEGAIS, INFORMO QUE CABE SER MANTIDA A EXTINCAO DA PATENTE E SEUS CERTIFICADOS, CONFORME O DISPOSTO NO ARTIGO 12, DA RESOLUCAO 113/2013. |

优先权:

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申请号 | 申请日 | 专利标题

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US12/882,538|US8613818B2|2010-09-15|2010-09-15|Processing routes for titanium and titanium alloys|

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PCT/US2011/048546|WO2012036841A1|2010-09-15|2011-08-22|Processing routes for titanium and titanium alloys|

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