Methods for producing forged products and other worked products
View Patent ↗Methods for producing forged products and other worked products are disclosed. In one embodiment, a method comprises using additive manufacturing to produce a metal shaped-preform and, after the using step, forging the metal shaped-preform into a final forged product. The final forged product may optionally be annealed.
1. A method comprising:
(a) using additive manufacturing to produce a metal shaped-preform, wherein the metal shaped-preform comprises a nickel 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 an opposing lower side of the building substrate;
wherein at least one of the first material, the second material and the building substrate comprises the nickel 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;
wherein the forging step (b) comprises non-uniformly applying strain to the metal shaped-preform via an impression die.
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 INCONEL.
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 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.
6. The method of claim 1 , wherein the final forged product is a blade for a jet engine.
7. 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.
8. A method comprising:
(a) using additive manufacturing to produce a metal shaped-preform, wherein the metal shaped-preform comprises an aluminum 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 an opposing lower side of the building substrate;
wherein at least one of the first material, the second material and the building substrate comprises the aluminum 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;
wherein the forging step (b) comprises non-uniformly applying strain to the metal shaped-preform via an impression die.
9. The method of claim 8 , 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.
10. The method of claim 8 , 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.
11. The method of claim 10 , 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.
12. The method of claim 8 , wherein the final forged product is a blade for a jet engine.
13. The method of claim 8 , 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.
14. The method of claim 1 , wherein the building substrate is a pre-wrought base plate.
15. The method of claim 1 , wherein the first material is different than the building substrate.
16. The method of claim 8 , wherein the building substrate is a pre-wrought base plate.
17. The method of claim 8 , wherein the first material is different than the building substrate.
18. A method comprising:
(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;
wherein at least one of the first material and the building substrate comprises the titanium alloy;
wherein the building substrate is a pre-wrought base plate; and
(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;
wherein the forging step (b) comprises non-uniformly applying strain to the metal shaped-preform via an impression die.
19. The method of claim 18 , wherein the forging step (b) 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.
20. The method of claim 18 , wherein the method comprises annealing the final forged product.