Methods for producing forged products and other worked products

1. A method compromising:

(a) using additive manufacturing to produce a metal shaped-preform, wherein the metal shaped-preform comprises a titanium alloy, wherein the additive manufacturing comprises:

depositing layers of a first material on an upper side of a building substrate; and

depositing layers of a second material on a opposing lower side of the building substrate;

wherein at least one of the first material, the second material, and the building substrate comprises the titanium alloy;

(b) after the using step (a), forging the metal shaped-preform, with the building substrate therein, into a final forged product having the building substrate therein.

2. The method of claim 1 , wherein the forging step comprises a single die forging step, wherein the single die forging step is using a single blocker die to die forge the metal-shaped preform into the final forged product.

3. The method of claim 1 , wherein at least one of the first material, the second material, or the building substrate of the metal shaped-preform comprises titanium aluminide.

4. The method of claim 1 , wherein the forging step comprises:

heating the metal shaped-preform to a stock temperature; and

contacting the metal shaped-preform with a forging die, wherein, when the contacting step is initiated, the forging die is a temperature that is at least 10° F. lower than the stock temperature.

5. The method of claim 1 , wherein the final forged product is a blade for a jet engine.

6. The method of claim 1 , wherein the titanium alloy includes at least 50 wt. % Ti and at least one titanium aluminide phase, wherein the at least one titanium aluminide phase is selected from the group consisting of Ti 3 Al, TiAl and combinations thereof.

7. The method of claim 6 , wherein the titanium alloy includes 5-30 wt. % aluminum, and the titanium alloy comprises at least some Ti 3 Al.

8. The method of claim 1 , wherein the titanium alloy is a Ti-6Al-4V alloy.

9. The method of claim 4 , wherein the contacting step comprises applying sufficient force to the metal shaped-preform via the forging die to realize a true strain of from 0.05 to 1.10 in the metal shaped-preform.

10. The method of claim 1 comprising,

after the forging step (b), annealing the final forged product.

11. The method of claim 10 , wherein at least one of the first material, the second material, or the building substrate of the metal shaped-preform comprises a Ti-6Al-4V alloy, and wherein the annealing step comprises heating the final forged product to a temperature of from 640° C. to 816° C.

12. The method of claim 11 , wherein the annealing step comprises heating the final forged product to a temperature of from 670° C. to 750° C.

13. The method of claim 1 , comprising:

prior to the using step, designing the shape of the building substrate such that, after the forging step, the building substrate is located in a predetermined area of low strain of the final forged product.