CN115780708A - Direct die forging forming method for nickel-based powder superalloy disc - Google Patents
Direct die forging forming method for nickel-based powder superalloy disc Download PDFInfo
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Abstract
The invention discloses a direct die forging forming method of a nickel-based powder superalloy disc, which comprises the following steps: cutting a blank from a nickel-based powder superalloy extrusion bar in a fine crystalline state; processing the nickel-based powder superalloy ingot blank according to the designed size and structure; respectively carrying out gradient heating treatment on the direct die forging forming die and the nickel-based powder superalloy ingot blank, and then transferring the nickel-based powder superalloy ingot blank into the direct die forging forming die; starting a hydraulic press to perform direct die forging forming on the nickel-based powder superalloy disc, and continuously adjusting the pressing speed in the forming process to control the strain rate within a certain range until the nickel-based powder superalloy disc is finally formed; and carrying out subsequent heat treatment. The invention really realizes the superplastic forming of the nickel-based powder superalloy disc, the prepared disc has low internal residual stress, the grain structure of different parts of the disc is about 6-9 grades, and the tensile and creep properties of the different parts of the disc all meet the technical index requirements.
Description
Technical Field
The invention belongs to the technical field of isothermal forging of powder superalloy, and particularly relates to a direct die forging forming method of a nickel-based powder superalloy disc.
Background
With the increase of the thrust-weight ratio of modern aeroengines, the manufacture of aeroengine turbine disks uses a large amount of high-alloying high-temperature alloy, and because of the increasing of alloy strengthening elements, the hot workability of the aeroengine turbine disks is deteriorated due to serious segregation. The nickel-based powder superalloy has the advantages of uniform structure, fine crystal grains, high yield strength, good fatigue performance and the like, and becomes a preferred material of a high-performance engine turbine disk with a thrust-weight ratio of more than 8. In European and American countries, nickel-based powder superalloy disk parts are mainly manufactured by adopting a large ferrous metal extruder to perform extrusion cogging so as to obtain a disk blank with a fine grain structure, and then performing superplastic isothermal forging under vacuum to form a turbine disk part, and 90% of the nickel-based powder superalloy parts in the United states are manufactured by adopting an extrusion and superplastic isothermal forging process route after 1995. In the present and future period, superplastic isothermal forging is one of the most reliable key technologies for producing nickel-based powder superalloy turbine disks.
With the gradual improvement of domestic hot extrusion equipment, in the twelve and five periods, china breaks through the extrusion technology of large-sized bars of nickel-based powder superalloy, prepares large-sized extruded bars which have uniform tissues and fine crystal grains and meet the requirements of models, and the crystal grain tissues of the extruded bars reach ASTM level 12 (the crystal grain size is about 7-8 mu m), thereby providing a tissue foundation for realizing superplastic forming of the nickel-based powder superalloy in the isothermal forging process. At present, the technological route for preparing the nickel-based powder superalloy turbine disc in China mainly comprises hot isostatic pressing, hot extrusion and isothermal forging under the atmosphere, but experts and scholars at home and abroad have less research on the deformation mechanism of the nickel-based powder superalloy superplastic isothermal forging, and a technological window for the nickel-based powder superalloy superplastic forming is not mastered.
For a long time, isothermal forging of nickel-based powder superalloy disc pieces is generally carried out by adopting a mode of pier cake and die forging, the forging period is long, the cost is high, disc piece forming is mainly carried out in a recrystallization mode mainly based on dislocation slippage, and the fundamental reason is that a superplastic forming process window of alloy is not obtained and the corresponding relation of different strain distributions of the disc pieces to tissues is not mastered.
The invention patent with application publication number CN114192719A discloses a high-temperature alloy extrusion-forging forming die, a method and application thereof, wherein the method comprises the following steps: putting a high-temperature alloy blank into a blank placing section of a die, placing an extrusion push rod and a forging press head on the high-temperature alloy blank, heating the high-temperature alloy blank and the die to a preset temperature and preserving heat; synchronously pressing down the extrusion push rod and the forging press head, so that the high-temperature alloy blank is extruded, deformed and refined into grains at the extrusion speed of the first stage, and the defects of the initial structure are eliminated; the extrusion push rod is kept still, the forging press head is pressed down at the second-stage die forging speed, the fine-grain high-temperature alloy is ejected out of the extrusion die cavity and enters the forging forming die cavity to continuously generate secondary plastic deformation, and finally the target structure forging piece is formed; wherein the first stage extrusion speed is greater than the second stage swaging speed. According to the technical scheme, two processes of extrusion cogging and isothermal forging are combined, although the two processes are combined through a die, the process route is still the traditional process of hot extrusion and isothermal forging, so that the defects still exist, large plastic deformation of a high-temperature alloy blank cannot be caused, a fine grain structure is generated, and a deformation dead zone exists at the same time; in addition, the process of putting extrusion and forging together has high requirements on equipment.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a direct die forging forming method of a nickel-based powder superalloy disk, which comprises the following steps in sequence:
the method comprises the following steps: cutting a blank from a nickel-based powder superalloy extrusion bar in a fine crystalline state;
step two: cutting an ingot blank with a certain size from the blank according to the material consumption of the nickel-based powder superalloy disc piece, and then designing the structure of the ingot blank according to the structure of the nickel-based powder superalloy disc piece; processing the alloy ingot blank into a nickel-based powder superalloy ingot blank according to the corresponding size and structure;
step three: blowing sand on the surface of the nickel-based powder superalloy ingot blank by using a sand blower, and then heating the surface of the ingot blank; after the heating treatment is finished, uniformly coating a glass lubricant on the surface of the nickel-based powder superalloy ingot blank;
step four: respectively carrying out gradient heating treatment on a direct die forging forming die of the nickel-based powder superalloy disc and a nickel-based powder superalloy ingot blank; after the gradient heating treatment is finished, transferring the nickel-based powder superalloy ingot blank into a direct die forging forming die, and positioning;
step five: starting an isothermal forging hydraulic press, performing direct die forging forming on the nickel-based powder superalloy disc, and continuously adjusting the pressing speed of the isothermal forging hydraulic press in the direct die forging forming process to control the strain rate within a certain range until the nickel-based powder superalloy disc is finally formed; taking out the nickel-based powder superalloy disc, covering at least two layers of aluminum silicate fiber felts, and slowly cooling;
step six: and carrying out heat treatment on the nickel-based powder superalloy disk piece after direct die forging forming to obtain the nickel-based powder superalloy disk piece.
Preferably, in the step one, the fine crystalline nickel-based powder superalloy extrusion bar is a bar structure with a grain size of not more than 10 μm, which is obtained by performing an extrusion process on the nickel-based powder superalloy at an extrusion temperature of 1050-1100 ℃ and an extrusion ratio of 5-8.
In any of the above schemes, preferably, in the step two, the equivalent strain is controlled within the range of 0.3-1.5 when the ingot blank structure of the nickel-based powder superalloy disk piece is designed. A large number of tests prove that the strain distribution of the nickel-based powder superalloy disk piece during direct die forging forming can be more uniform only if the equivalent strain is controlled within the range of 0.3-1.5, and the optimal strain distribution state is achieved. When the equivalent strain is less than 0.3, a coarse-grain structure can appear on the disc; when the equivalent strain is more than 1.5, the grain structure of the disc is too fine to be favorable for creep performance.
According to the invention, when an ingot blank structure of the nickel-based powder superalloy disc piece is designed, numerical simulation software such as Deform, marc and Abaqus is adopted for simulation by means of a finite element analysis method. In the process of numerical simulation, the equivalent strain is controlled within the range of 0.3-1.5, and the disc structure formed by the equivalent strain within the range is restored to obtain the ingot blank structure of the nickel-based powder superalloy disc.
In any of the above schemes, preferably, in step three, the surface heating process of the nickel-based powder superalloy ingot blank is as follows: the heating temperature is 80-200 ℃, and the heating time is 0.5-1h.
In any of the above schemes, preferably, in step four, the gradient heating process of the direct die forging forming die is as follows: heating to 250-350 deg.C from room temperature at a heating rate of 8-10 deg.C/min, and maintaining for 3.5-4.5h; continuously heating to 550-650 ℃ at the heating rate of 8-10 ℃/min, and preserving the heat for 5.5-6.5h; continuously heating to 850-950 ℃ at the heating rate of 10-15 ℃/min, and keeping the temperature for 5.5-6.5h; continuously heating to 1050-1100 ℃ at the heating rate of 10-15 ℃/min, and keeping the temperature for at least 7h. A large number of tests prove that after the direct die forging forming die is treated by the gradient heating process, the die can be fully and uniformly heated, and meanwhile, the required temperature is reached.
In any of the above schemes, preferably, in step four, the gradient heating process of the nickel-based powder superalloy ingot blank is as follows: putting the nickel-based powder superalloy ingot blank into a heating furnace, heating the ingot blank from room temperature to 550-650 ℃ at the heating rate of 5-8 ℃/min, and preserving the heat for 2.5-3.5h; continuously heating to 750-850 ℃ at the heating rate of 3-5 ℃/min, and keeping the temperature for 1.5-2.5h; continuously heating to 1050-1100 ℃ at the heating rate of 3-5 ℃/min, and keeping the temperature for 4.5-5.5h. A large number of tests prove that the nickel-based powder superalloy ingot blank can be fully and uniformly heated after being treated by the gradient heating process, and the dislocation density in the alloy is reduced to the maximum extent.
In any of the above schemes, preferably, in the fourth step, the time for transferring the nickel-based powder superalloy ingot into the direct forging forming die is not more than 60s. In the invention, the nickel-based powder superalloy ingot blank is rapidly transferred to a direct die forging forming die, so that the temperature reduction of the ingot blank in the transfer process is reduced as much as possible.
In any of the above aspects, it is preferable that the strain rate is controlled to be 3.2 × 10 during the direct die forging of the nickel-based powder superalloy disk member in the fifth step -4 ～9.6×10 -4 s -1 Within the range. In the invention, the pressing speed of the isothermal forging hydraulic press is continuously adjusted according to the height of the nickel-based powder superalloy ingot blank in the pressing process, and the strain rate is required to be always kept at 3.2 multiplied by 10 -4 ～9.6×10 -4 s -1 Within the range, so that the disc part is formed by a superplastic deformation mechanism mainly based on grain boundary migration. The adjustment of the pressing speed is gradient deceleration, and the specific speed is adjusted according to the actual conditions of the structure, the height and the like of the disc.
In the direct die forging forming process of the nickel-based powder superalloy disc piece, equivalent strain and strain rate are two key and important process windows, the equivalent strain must be controlled within the range of 0.3-1.5, and the strain rate must be controlled within 3.2 multiplied by 10 -4 ～9.6×10 -4 s -1 Within the range, the direct super-plastic die forging forming of the nickel-based powder high-temperature alloy disc piece under the atmosphere can be realized, and the direct die forging forming is one-shot forming.
In the invention, the sand blower, the isothermal forging hydraulic press, the heating furnace and the like are all test equipment commonly used in the field, and the model of the equipment is not required; the formula and the preparation process of the nickel-based powder superalloy are not required, and the nickel-based powder superalloy is prepared by adopting the prior art or the traditional technology; the nickel-based powder high-temperature alloy disc formed by superplastic direct die forging needs subsequent heat treatment, namely solid solution and aging treatment, does not require a solid solution and aging treatment system, and only needs to adopt the existing system.
The direct die forging forming method of the nickel-based powder superalloy disc piece provides a process window for superplastic direct die forging forming of the nickel-based powder superalloy disc piece, and realizes real superplastic forming, namely forming by a deformation mechanism mainly based on grain boundary migration, the prepared disc piece is low in internal residual stress and uniform in structure, the grain structure of different parts of the disc piece is about 6-9 grades, the tensile and creep properties of the different parts of the disc piece all meet the technical index requirements, meanwhile, the superplastic one-shot forming of the disc piece can be realized, the forging period is greatly shortened, and the forging cost is greatly reduced.
The direct die forging forming method of the nickel-based powder superalloy disc piece has the beneficial effects that:
(1) The method for preparing the nickel-based powder superalloy disk part can shorten the forging period by 50 percent;
(2) The nickel-based powder superalloy disk prepared by the method can reduce the forging cost by 50%;
(3) The nickel-based powder superalloy disk prepared by the method can reduce the internal residual stress of the disk by at least 10%, and the grain structure and the mechanical property all meet the requirements of technical indexes.
Drawings
FIG. 1 is a schematic structural view of a nickel-based powder superalloy ingot blank in a preferred embodiment of a direct die forging method for forming a nickel-based powder superalloy disk in accordance with the present invention;
FIG. 2 is a photograph of a nickel-based powder superalloy disk of the embodiment of FIG. 1 after being subjected to superplastic direct forging;
FIG. 3 is a schematic longitudinal cross-sectional view of a nickel-based powder superalloy disk of the embodiment of FIG. 1, wherein: (1) ⑫ is the hub, ⑬ - ⑳ is the web, A-F are the rims, a-i are the sample rings;
FIG. 4 is a metallographic photograph of the grain structure of different portions of the nickel-based powder superalloy disk in the embodiment shown in FIG. 1, wherein: the metallographic structure of the part (1) is shown in the formula (1), (2) is shown in the metallographic structure of the part (3), (3) is shown in the metallographic structure of the part (6), (4) is shown in the metallographic structure of the part (r), (5) is shown in the metallographic structure of the part ⑭, (6) is shown in the metallographic structure of the part ⑰, (7) is shown in the metallographic structure of the part B, and (8) is shown in the metallographic structure of the part e.
FIG. 5 is a schematic structural view of a nickel-based powder superalloy ingot blank in another preferred embodiment of a direct die forging method of a nickel-based powder superalloy disk in accordance with the present invention;
FIG. 6 is a photograph of a nickel-based powder superalloy disk of the embodiment of FIG. 5 after being subjected to superplastic direct forging;
FIG. 7 is a schematic longitudinal cross-sectional view of the nickel-based powder superalloy disk of the embodiment of FIG. 5, wherein: (1) ⑫ is the hub, A-H is the web, ⑬ - ⑱ is the rim, a-i is the sample ring;
FIG. 8 is a metallographic photograph of the grain structure of different portions of the nickel-based powder superalloy disk of the embodiment of FIG. 5, wherein: the metallographic structure of the part (1) is shown in the specification, (2) the metallographic structure of the part (3) is shown in the specification, (3) the metallographic structure of the part (6) is shown in the specification, (4) the metallographic structure of the part (r) is shown in the specification, (5) the metallographic structure of the part (B) is shown in the specification, (6) the metallographic structure of the part (E) is shown in the specification, (7) the metallographic structure of the part ⑭ is shown in the specification, and (8) the metallographic structure of the part (E) is shown in the specification.
Detailed Description
In order that the invention may be further understood, the invention will now be described in detail with reference to specific examples.
The first embodiment is as follows:
according to a preferred embodiment of the direct die forging forming method of the nickel-based powder superalloy disc piece, the method comprises the following steps in sequence:
the method comprises the following steps: cutting a blank from a nickel-based powder superalloy extrusion bar in a fine crystalline state;
step two: cutting an ingot blank with a certain size from the blank according to the material consumption of the nickel-based powder superalloy disc piece, and then designing the structure of the ingot blank according to the structure of the nickel-based powder superalloy disc piece; processing the alloy ingot blank into a nickel-based powder superalloy ingot blank according to the corresponding size and structure;
step three: blowing sand on the surface of the nickel-based powder superalloy ingot blank by using a sand blower, and then heating the surface of the ingot blank; after the heating treatment is finished, uniformly coating a glass lubricant on the surface of the nickel-based powder superalloy ingot blank;
step four: respectively carrying out gradient heating treatment on a direct die forging forming die of the nickel-based powder superalloy disc and a nickel-based powder superalloy ingot blank; after the gradient heating treatment is finished, transferring the nickel-based powder superalloy ingot blank into a direct die forging forming die, and positioning;
step five: starting an isothermal forging hydraulic press, performing direct die forging forming on the nickel-based powder superalloy disc, and continuously adjusting the pressing speed of the isothermal forging hydraulic press in the direct die forging forming process to control the strain rate within a certain range until the nickel-based powder superalloy disc is finally formed; taking out the nickel-based powder superalloy disc, covering at least two layers of aluminum silicate fiber felts, and slowly cooling the nickel-based powder superalloy disc;
step six: and carrying out heat treatment on the nickel-based powder superalloy disk piece formed by direct die forging to obtain the nickel-based powder superalloy disk piece.
In the first step, the FGH96 alloy is adopted in this embodiment, the fine crystalline nickel-based powder superalloy extrusion bar is a bar structure with a grain size not greater than 10 μm obtained by subjecting the nickel-based powder superalloy to an extrusion process at an extrusion temperature of 1050 ℃ and an extrusion ratio of 8, and the diameter of the extrusion bar is 250mm.
In the second step, when the ingot blank structure of the nickel-based powder superalloy disc is designed, the equivalent strain is 0.3. A large number of tests prove that the equivalent strain needs to be controlled within the range of 0.3-1.5, so that the strain distribution of the nickel-based powder superalloy disc piece during direct die forging forming is more uniform, and the optimal strain distribution state is achieved. When the equivalent strain is less than 0.3, the disc part has a coarse-grained structure; when the equivalent strain is larger than 1.5, the grain structure of the disc is too fine to be favorable for creep performance.
In the embodiment, when the ingot blank structure of the nickel-based powder superalloy disc is designed, numerical simulation software such as form, marc, abaqus and the like can be adopted for simulation by means of a finite element analysis method. In the process of numerical simulation, the equivalent strain is controlled within the range of 0.3-1.5, the structure of the disc part formed by the equivalent strain within the range is restored, the ingot blank structure of the nickel-based powder superalloy disc part can be obtained, as shown in figure 1, and then the ingot blank with the diameter of 240mm multiplied by 250mm is processed according to the structure shown in figure 1.
In the third step, the surface heating process of the nickel-based powder superalloy ingot blank comprises the following steps: the heating temperature is 80 ℃, and the heating time is 1h.
In the fourth step, the gradient heating process of the direct die forging forming die comprises the following steps: heating from room temperature to 250 ℃ at the heating rate of 8 ℃/min, and keeping the temperature for 4.5h; continuously heating to 550 ℃ at the heating rate of 8 ℃/min, and keeping the temperature for 6.5h; continuously heating to 850 ℃ at the heating rate of 10 ℃/min, and keeping the temperature for 6.5h; the temperature is continuously raised to 1050 ℃ at the temperature raising speed of 10 ℃/min, and the temperature is kept for 7h. A large number of tests prove that the direct die forging forming die can ensure that the die is fully and uniformly heated after being treated by the gradient heating process and simultaneously reaches the required temperature.
The gradient heating process of the nickel-based powder superalloy ingot blank comprises the following steps: putting the nickel-based powder superalloy ingot blank into a heating furnace, heating the ingot blank from room temperature to 550 ℃ at the heating speed of 5 ℃/min, and preserving the heat for 3.5 hours; continuously heating to 750 ℃ at the heating rate of 3 ℃/min, and keeping the temperature for 2.5h; the temperature is continuously raised to 1050 ℃ at the temperature raising speed of 3 ℃/min, and the temperature is kept for 5.5h. A large number of tests prove that the nickel-based powder superalloy ingot blank can be fully and uniformly heated after being treated by the gradient heating process, and the dislocation density in the alloy is reduced to the maximum extent.
The time for transferring the nickel-based powder superalloy ingot into the direct forging forming die is not more than 60 seconds. In the embodiment, the nickel-based powder superalloy ingot blank is rapidly transferred to a direct die forging forming die, so that the temperature reduction of the ingot blank in the transfer process is reduced as much as possible.
In the fifth step, the strain rate is 3.2 multiplied by 10 in the direct die forging forming process of the nickel-based powder superalloy disk piece -4 s -1 . In this embodiment, the pressing process should be based onThe pressing speed of the isothermal forging hydraulic press is continuously adjusted by the height of the medium nickel-based powder superalloy ingot blank, and the strain rate is always kept at 3.2 multiplied by 10 -4 ～9.6×10 -4 s -1 Within the range, so that the disc part is formed by a superplastic deformation mechanism mainly based on grain boundary migration. The adjustment of the pressing speed is gradient deceleration, and the specific speed is adjusted according to the actual conditions of the structure, the height and the like of the disc. In this embodiment, the initial pressing speed of the hydraulic press is 0.15mm/s, the pressing speed is adjusted to 0.1mm/s when the height of the ingot blank is 160mm, the pressing speed is adjusted to 0.05mm/s when the height of the ingot blank is 110mm, the pressing is stopped when the height of the ingot blank is 99.5mm, the pressure is maintained for 10 seconds, the disc is ejected by the ejector rod, and then the disc is taken out by the mechanical handle.
In the direct die forging forming process of the nickel-based powder superalloy disc piece, equivalent strain and strain rate are two key and important process windows, the equivalent strain must be controlled within the range of 0.3-1.5, and the strain rate must be controlled within 3.2 multiplied by 10 -4 ～9.6×10 -4 s -1 Within the range, the direct super-plastic die forging forming of the nickel-based powder high-temperature alloy disc piece under the atmosphere can be realized, and the direct die forging forming is one-shot forming.
Fig. 2 is a nickel-based powder superalloy disc formed by superplastic direct die forging, the disc is subjected to anatomical analysis, the structure and the performance of the disc are detected and tested, the longitudinal section of the disc is shown in fig. 3, the grain structures of different parts on the disc are shown in fig. 4, the grain size is in the range of ASTM7-8.5 grade, and the technical index requirements (the grain size is 6 grade or finer) are met, wherein: the grain size of portion (1) is 8.5 grade, the grain size of portion (3) is 8.5 grade, the grain size of portion (6) is 8.5 grade, the grain size of portion (r) is 8 grade, the grain size of portion ⑭ is 8 grade, the grain size of portion ⑰ is 7 grade, the grain size of portion B is 8 grade, and the grain size of portion e is 8 grade. The tensile property and the creep property are shown in tables 1-4, and both meet the technical index requirements.
In the embodiment, the sand blower, the isothermal forging hydraulic machine, the heating furnace and the like are all test equipment commonly used in the field, and the model of the equipment is not required; the formula and the preparation process of the nickel-based powder superalloy are not required, and the nickel-based powder superalloy is prepared by adopting the prior art or the traditional technology; the nickel-based powder high-temperature alloy disc formed by superplastic direct die forging needs subsequent heat treatment, namely solid solution and aging treatment, does not require a solid solution and aging treatment system, and only needs to adopt the existing system. The disc piece is subjected to the conventional solution treatment and the aging treatment at 760 ℃/16 h.
The direct die forging forming method for the nickel-based powder superalloy disc piece provides a process window for superplastic direct die forging forming of the nickel-based powder superalloy disc piece, and realizes real superplastic forming, namely forming by a deformation mechanism mainly based on grain boundary migration, the prepared disc piece is low in internal residual stress and uniform in structure, the grain structure of different parts of the disc piece is about 6-9 grades, the tensile and creep properties of the different parts of the disc piece all meet the technical index requirements, and meanwhile, the superplastic one-shot forming of the disc piece can be realized. Has the advantages that: the nickel-based powder superalloy disk prepared by the method can shorten the forging period by 50 percent; the nickel-based powder superalloy disk prepared by the method can reduce the forging cost by 50%; the nickel-based powder superalloy disk prepared by the method can reduce the internal residual stress of the disk by at least 10%, and the grain structure and the mechanical property all meet the requirements of technical indexes.
Example two:
according to another preferred embodiment of the direct die forging forming method of the nickel-based powder superalloy disc piece, the process steps, the used test equipment, the principle, the beneficial effects and the like are basically the same as those of the first embodiment, except that:
in the first step, the FGH96 alloy is adopted in this embodiment, the fine crystalline nickel-based powder superalloy extrusion bar is a bar structure with a grain size not greater than 10 μm obtained by subjecting the nickel-based powder superalloy to an extrusion process at an extrusion temperature of 1100 ℃ and an extrusion ratio of 5, and the diameter of the extrusion bar is 230mm.
In the second step, when an ingot blank structure of the nickel-based powder superalloy disc is designed, the equivalent strain is 1.5. A large number of tests prove that the equivalent strain needs to be controlled within the range of 0.3-1.5, so that the strain distribution of the nickel-based powder superalloy disc piece during direct die forging forming is more uniform, and the optimal strain distribution state is achieved. When the equivalent strain is less than 0.3, the disc part has a coarse-grained structure; when the equivalent strain is more than 1.5, the grain structure of the disc is too fine to be favorable for creep performance.
In this embodiment, when designing the ingot blank structure of the nickel-based powder superalloy disc, numerical simulation software such as Deform, marc, abaqus and the like may be used for simulation by means of a finite element analysis method. In the process of numerical simulation, the equivalent strain is controlled within the range of 0.3-1.5, the structure of the disc part formed by the equivalent strain within the range is restored, the ingot blank structure of the nickel-based powder superalloy disc part can be obtained, as shown in fig. 5, and then the ingot blank with the diameter of 230mm multiplied by 290mm is processed according to the structure shown in fig. 5.
In the third step, the surface heating process of the nickel-based powder superalloy ingot blank comprises the following steps: the heating temperature is 200 ℃, and the heating time is 0.5h.
In the fourth step, the gradient heating process of the direct die forging forming die comprises the following steps: heating from room temperature to 350 ℃ at the heating rate of 10 ℃/min, and keeping the temperature for 3.5h; continuously heating to 650 ℃ at the heating rate of 10 ℃/min, and keeping the temperature for 5.5h; continuously heating to 950 ℃ at the heating rate of 15 ℃/min, and keeping the temperature for 5.5h; the temperature is continuously raised to 1100 ℃ at the temperature raising speed of 15 ℃/min, and the temperature is kept for 7h.
The gradient heating process of the nickel-based powder superalloy ingot blank comprises the following steps: putting the nickel-based powder superalloy ingot blank into a heating furnace, heating the ingot blank from room temperature to 650 ℃ at the heating speed of 8 ℃/min, and keeping the temperature for 2.5 hours; continuously heating to 850 ℃ at the heating rate of 5 ℃/min, and keeping the temperature for 1.5h; the temperature is continuously raised to 1100 ℃ at the temperature raising speed of 5 ℃/min, and the temperature is kept for 4.5h.
The time for transferring the nickel-based powder superalloy ingot into the direct die forging forming die is not more than 60s.
In the fifth step, the strain rate is 9.6 multiplied by 10 in the direct die forging forming process of the nickel-based powder superalloy disk piece -4 s -1 . In this example, the pressing speed of the isothermal forging hydraulic press should be continuously adjusted according to the height of the nickel-based powder superalloy ingot blank during pressing, and the strain rate should be kept at 3.2 × 10 -4 ～9.6×10 -4 s -1 Within the range, so that the disc part is formed by a superplastic deformation mechanism mainly based on grain boundary migration. The adjustment of the pressing speed is gradient deceleration, and the specific speed is adjusted according to the actual conditions of the structure, the height and the like of the disc. In this embodiment, the initial pressing speed of the hydraulic press is 0.20mm/s, the pressing speed is adjusted to 0.15mm/s when the height of the ingot blank is 210mm, the pressing speed is adjusted to 0.1mm/s when the height of the ingot blank is 150mm, the pressing speed is adjusted to 0.05mm/s when the height of the ingot blank is 110mm, the pressing is stopped when the height of the ingot blank is 99.5mm, the pressing is stopped after 10 seconds of pressure maintaining, the disc is ejected by the ejector rod, and then the disc is taken out by the mechanical handle.
Fig. 6 is a nickel-based powder superalloy disc formed by superplastic direct die forging, the disc is subjected to anatomical analysis, the structure and the performance of the disc are detected and tested, the longitudinal section of the disc is shown in fig. 7, the grain structures of different parts on the disc are shown in fig. 8, the grain size is in the range of ASTM7-8.5 grade, and the technical index requirements (the grain size is 6 grade or finer) are met, wherein: the grain size of site (1) is 8.5 grade, the grain size of site (3) is 8.5 grade, the grain size of site (6) is 8.5 grade, the grain size of site in r is 8.5 grade, the grain size of site B is 8.5 grade, the grain size of site E is 8 grade, the grain size of site ⑭ is 8 grade, and the grain size of site E is 8 grade. The tensile property and the creep property are shown in tables 5-8, and both meet the technical index requirements.
Example three:
according to another preferred embodiment of the direct die forging forming method of the nickel-based powder superalloy disc piece, the process steps, the used test equipment, the principle, the beneficial effects and the like are basically the same as those of the first embodiment, except that:
in the first step, FGH96 alloy is adopted in this embodiment, and the fine crystalline nickel-based powder superalloy extrusion bar is a bar structure with a grain size not greater than 10 μm obtained by subjecting the nickel-based powder superalloy to an extrusion process at an extrusion temperature of 1080 ℃ and an extrusion ratio of 7.
In the second step, when an ingot blank structure of the nickel-based powder superalloy disc is designed, the equivalent strain is 1.0. A large number of tests prove that the equivalent strain needs to be controlled within the range of 0.3-1.5, so that the strain distribution of the nickel-based powder superalloy disc piece during direct die forging forming is more uniform, and the optimal strain distribution state is achieved. When the equivalent strain is less than 0.3, the disc part has a coarse-grained structure; when the equivalent strain is larger than 1.5, the grain structure of the disc is too fine to be favorable for creep performance.
In this embodiment, when designing the ingot blank structure of the nickel-based powder superalloy disc, numerical simulation software such as Deform, marc, abaqus and the like may be used for simulation by means of a finite element analysis method. In the process of numerical simulation, the equivalent strain is controlled within the range of 0.3-1.5, and the disc structure formed by the equivalent strain within the range is restored to obtain the ingot blank structure of the nickel-based powder superalloy disc.
In the third step, the surface heating process of the nickel-based powder superalloy ingot blank comprises the following steps: the heating temperature is 120 ℃, and the heating time is 0.8h.
In the fourth step, the gradient heating process of the direct die forging forming die comprises the following steps: heating from room temperature to 300 ℃ at the heating rate of 9 ℃/min, and keeping the temperature for 4h; continuously heating to 600 ℃ at the heating rate of 9 ℃/min, and keeping the temperature for 6h; continuously heating to 900 ℃ at the heating rate of 12 ℃/min, and keeping the temperature for 6h; continuously heating to 1080 ℃ at the heating rate of 12 ℃/min, and preserving heat for 7h.
The gradient heating process of the nickel-based powder superalloy ingot blank comprises the following steps: putting the nickel-based powder superalloy ingot blank into a heating furnace, heating from room temperature to 600 ℃ at the heating rate of 6 ℃/min, and keeping the temperature for 3 hours; continuously heating to 800 ℃ at the heating rate of 4 ℃/min, and keeping the temperature for 2h; continuously heating to 1090 ℃ at the heating rate of 4 ℃/min, and preserving heat for 5h.
The time for transferring the nickel-based powder superalloy ingot into the direct forging forming die is not more than 60 seconds.
In the fifth step, the strain rate is 6.4 multiplied by 10 in the direct die forging forming process of the nickel-based powder superalloy disk piece -4 s -1 . In this example, the pressing speed of the isothermal forging hydraulic press should be continuously adjusted according to the height of the nickel-based powder superalloy ingot blank during pressing, and the strain rate should be kept at 3.2 × 10 -4 ～9.6×10 -4 s -1 Within the range, so as to ensure that the disc part is formed by a superplastic deformation mechanism taking grain boundary migration as a main part.
Specifically, the following description is provided: the technical scheme of the invention relates to a plurality of parameters, and the beneficial effects and the remarkable progress of the invention can be obtained only by comprehensively considering the synergistic effect among the parameters. In addition, in the technical scheme, the value ranges of the parameters are obtained through a large number of tests, and for each parameter and the mutual combination of the parameters, the inventor records a large number of test data, which is limited to space, and specific test data are not disclosed herein.
It will be understood by those skilled in the art that the direct die forging method for forming a nickel-based powder superalloy disk member of the present invention includes any combination of the above summary and detailed description of the present invention, and the portions illustrated in the drawings, which are not described in detail and are not intended to be a brief description of the present description. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (8)
1. A direct die forging forming method of a nickel-based powder superalloy disc comprises the following steps in sequence:
the method comprises the following steps: cutting a blank from a nickel-based powder superalloy extrusion bar in a fine crystalline state;
step two: cutting an ingot blank with a certain size from the blank according to the material consumption of the nickel-based powder superalloy disc piece, and then designing the structure of the ingot blank according to the structure of the nickel-based powder superalloy disc piece; processing the alloy ingot blank into a nickel-based powder superalloy ingot blank according to the corresponding size and structure;
step three: blowing sand on the surface of the nickel-based powder superalloy ingot blank by using a sand blower, and then heating the surface of the ingot blank; after the heating treatment is finished, uniformly coating a glass lubricant on the surface of the nickel-based powder superalloy ingot blank;
step four: respectively carrying out gradient heating treatment on a direct die forging forming die of the nickel-based powder superalloy disc and a nickel-based powder superalloy ingot blank; after the gradient heating treatment is finished, transferring the nickel-based powder superalloy ingot blank into a direct die forging forming die, and positioning;
step five: starting an isothermal forging hydraulic press, performing direct die forging forming on the nickel-based powder superalloy disc, and continuously adjusting the pressing speed of the isothermal forging hydraulic press in the direct die forging forming process to control the strain rate within a certain range until the nickel-based powder superalloy disc is finally formed; taking out the nickel-based powder superalloy disc, covering at least two layers of aluminum silicate fiber felts, and slowly cooling the nickel-based powder superalloy disc;
step six: and carrying out heat treatment on the nickel-based powder superalloy disk piece formed by direct die forging to obtain the nickel-based powder superalloy disk piece.
2. The direct die forging method of a nickel-based powder superalloy disc of claim 1, wherein: in the first step, the fine crystalline nickel-based powder superalloy extrusion bar is a bar structure with the grain size not larger than 10 microns, which is obtained by performing an extrusion process on a nickel-based powder superalloy at an extrusion temperature of 1050-1100 ℃ and an extrusion ratio of 5-8.
3. The direct die forging method of a nickel-based powder superalloy disc of claim 1, wherein: in the second step, when the ingot blank structure of the nickel-based powder superalloy disc is designed, the equivalent strain is controlled within the range of 0.3-1.5.
4. The direct die forging method of a nickel-based powder superalloy disc of claim 1, wherein: in the third step, the surface heating process of the nickel-based powder superalloy ingot blank is that the heating temperature is 80-200 ℃, and the heating time is 0.5-1h.
5. The direct die forging method of a nickel-based powder superalloy disc of claim 1, wherein: in the fourth step, the gradient heating process of the direct die forging forming die is that the temperature is raised from room temperature to 250-350 ℃ at the temperature raising speed of 8-10 ℃/min, and the temperature is kept for 3.5-4.5h; continuously heating to 550-650 ℃ at the heating rate of 8-10 ℃/min, and preserving heat for 5.5-6.5h; continuously heating to 850-950 ℃ at the heating rate of 10-15 ℃/min, and keeping the temperature for 5.5-6.5h; continuously heating to 1050-1100 ℃ at the heating rate of 10-15 ℃/min, and keeping the temperature for at least 7h.
6. The direct die forging method of a nickel-based powder superalloy disc according to claim 5, wherein: step four, the gradient heating process of the nickel-based powder superalloy ingot blank comprises the steps of putting the nickel-based powder superalloy ingot blank into a heating furnace, heating the nickel-based powder superalloy ingot blank from room temperature to 550-650 ℃ at the heating rate of 5-8 ℃/min, and keeping the temperature for 2.5-3.5 hours; continuously heating to 750-850 ℃ at the heating rate of 3-5 ℃/min, and keeping the temperature for 1.5-2.5h; continuously heating to 1050-1100 ℃ at the heating rate of 3-5 ℃/min, and keeping the temperature for 4.5-5.5h.
7. The direct die forging method of a nickel-based powder superalloy disc of claim 6, wherein: in the fourth step, the time for transferring the nickel-based powder superalloy ingot blank into the direct forging forming die is not more than 60s.
8. The direct die forging method of a nickel-based powder superalloy disc of claim 1, wherein: in the fifth step, the strain rate is controlled to be 3.2 multiplied by 10 in the direct die forging forming process of the nickel-based powder superalloy disk piece -4 ～9.6×10 -4 s -1 Within the range.
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