Abstract:
Processes and methods related to producing, processing, and hot working alloy ingots are disclosed. An alloy ingot is formed including an inner ingot core and an outer layer metallurgically bonded to the inner ingot core. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.
Abstract:
A system and method of processing an alloy ingot or other alloy workpiece to reduce thermal cracking and reduce friction between the workpiece and the forging die may generally comprise positioning a multi-layer pad between the workpiece and the forging die. An article for processing an alloy ingot or other alloy workpiece to reduce thermal cracking also is disclosed. The present disclosure also is directed to an alloy workpieces processed according to the methods described herein, and to articles of manufacture including or made from alloy workpieces made according to these methods.
Abstract:
A casting system and method. The casting system can include an energy source and a hearth, which can have a tapered cavity. The tapered cavity can have a first end portion and a second end portion, and the tapered cavity can narrow between the first and second end portions. Further, the tapered cavity can have an inlet at the first end portion that defines an inlet capacity, and one or more outlets at the second end portion that define an outlet capacity. Where the cavity has a single outlet, the outlet capacity can be less than the inlet capacity. Where the cavity has multiple outlets, the combined outlet capacity can match the inlet capacity. Further, the cross-sectional area of the tapered cavity near the inlet can be similar to the cross-sectional area of the inlet.
Abstract:
A forging die heating or preheating apparatus comprises a burner head comprising a plurality of flame ports. The burner head is oriented to compliment an orientation of at least a region of a forging surface of a forging die and is configured to receive and combust a supply of an oxidizing gas and a supply of a fuel and produce flames at the flame ports. The plurality of flame ports are configured to impinge the flames onto the forging surface of the forging die to substantially uniformly heat at least the region of the forging surface of the forging die.
Abstract:
A method of processing a metal alloy includes heating to a temperature in a working temperature range from a recrystallization temperature of the metal alloy to a temperature less than an incipient melting temperature of the metal alloy, and working the alloy. At least a surface region is heated to a temperature in the working temperature range. The surface region is maintained within the working temperature range for a period of time to recrystallize the surface region of the metal alloy, and the alloy is cooled so as to minimize grain growth. In embodiments including superaustenitic and austenitic stainless steel alloys, process temperatures and times are selected to avoid precipitation of deleterious intermetallic sigma-phase. A hot worked superaustenitic stainless steel alloy having equiaxed grains throughout the alloy is also disclosed.
Abstract:
A method of processing a non-magnetic alloy workpiece comprises heating the workpiece to a warm working temperature, open die press forging the workpiece to impart a desired strain in a central region of the workpiece, and radial forging the workpiece to impart a desired strain in a surface region of the workpiece. In a non-limiting embodiment, after the steps of open die press forging and radial forging, the strain imparted in the surface region is substantially equivalent to the strain imparted in the central region. In another non-limiting embodiment, the strain imparted in the central and surface regions are in a range from 0.3 inch/inch to 1 inch/inch, and there exists no more than a 0.5 inch/inch difference in strain of the central region compared with the strain of the surface region of the workpiece. An alloy forging processed according to methods described herein also is disclosed.
Abstract:
A method of processing an alloy ingot or other alloy workpiece to reduce thermal cracking may generally comprise depositing a glass material onto at least a portion of a surface of a workpiece, and heating the glass material to form a surface coating on the workpiece that reduces heat loss from the workpiece. The present disclosure also is directed to an alloy workpieces processed according to methods described herein, and to articles of manufacture including or made from alloy workpieces made according to the methods.