A method of manufacturing a nickel-based alloy cartridge

Abstract

The present application relates to a kind of nickel-based alloy cartridge manufacturing method, comprising orthogonal experiment steps: blank edge sampling, edge to center sampling;Sample heating and heat preservation, after solution detection sample grain size;Determine forging temperature;Sample cutting sample, sample is heated after upsetting according to different deformation amount, and test sample grain size;Determine forging deformation amount;Upsetting punching step: blank is heated to forging temperature, and is punched;Final forging temperature is: 950 DEG C;Air cooling to room temperature;Hole expansion forging step: blank is heated to forging temperature, and is expanded;Blank hole expansion deformation is forging deformation amount;Final forging temperature is: 950 DEG C;Air cooling to room temperature;Final rolling forging step: blank is heated to forging temperature, and is rolled;Blank rolling deformation is forging deformation amount;Final forging temperature is greater than or equal to 950 DEG C;Air cooling to room temperature to form product.Solve the problem in prior art scheme, selected forging temperature is lower, and it is easy to produce forging crack and forging deformation amount is smaller, and forging fire time is more.

Description

Technical Field

[0001] This invention relates to the field of forging methods, and more particularly to a method for manufacturing a nickel-based alloy casing. Background Technology

[0002] Nickel-based alloy casings are one of the most important components of civil aircraft engines. They have extremely high requirements for the uniformity of the microstructure and performance of the product. Nickel-based alloy casings are difficult to billet and the material is very prone to cracking. Furthermore, nickel-based alloys have extremely stringent requirements for dynamic recrystallization conditions. If not properly controlled, they are very easy to cause mixed crystals and coarse grains.

[0003] Traditional manufacturing parameters for nickel-based alloy casings (mainly temperature and deformation) are based on experience, and the selected parameters typically have limitations. First, the selected temperature is generally low, usually at or below the solution treatment temperature. Using these parameters requires large equipment tonnage, typically ranging from 20,000 to 40,000 tons, drastically increasing production costs. It also increases the risk of cracking during forging, leading to product scrap, insufficient dynamic recrystallization, and a high likelihood of mixed crystal formation, resulting in either rejection or scrap. Second, the selected deformation is relatively small, requiring more heat treatments, which also increases production costs. Therefore, addressing this issue is crucial. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the purpose of this invention is to provide a method for manufacturing a nickel-based alloy casing, so as to solve the problems of the prior art, which is that the forging temperature is low, the equipment tonnage is large during forging, forging cracks are easy to occur, and the forging deformation is small, resulting in a large number of forging passes.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows:

[0006] A method for manufacturing a nickel-based alloy casing;

[0007] Includes the following steps:

[0008] Orthogonal experimental procedure: Samples are taken sequentially along the edge of the billet, and then samples are taken sequentially from the edge to the center; the samples are heated and held at that temperature, and then the grain size of the samples is measured after solution treatment; the forging temperature is determined by the grain size of the samples.

[0009] The sample is cut into specimens, which are then upset and heat-treated according to different deformation amounts. The grain size of the specimens is then measured, and the forging deformation amount is determined by the grain size of the specimens.

[0010] Upsetting and punching steps: Heat the billet to the forging temperature, then perform upsetting and punching; the final forging temperature is 950℃; then air cool to room temperature;

[0011] Hole reaming forging steps: Heat the billet to the forging temperature, then ream the hole; the deformation amount of the billet during hole reaming is the forging deformation amount; the final forging temperature is 950℃; then air cool to room temperature;

[0012] Final rolling forging steps: The billet is heated to the forging temperature and then rolled; the rolling deformation of the billet is the forging deformation; the final forging temperature is ≥950℃; then it is air-cooled to room temperature to form the product.

[0013] Further technical solutions are as follows: In the orthogonal experimental steps: the sampling area density in the sampling path is 10-15%; the corners of the sampling shape are rounded.

[0014] A further technical solution is as follows: In the orthogonal experimental procedure, the samples are divided into several groups according to the holding time; several samples in a single group are heated at different temperatures.

[0015] A further technical solution is as follows: In the orthogonal experimental procedure, the samples are divided into several groups according to the heating temperature; several samples in a single group are forged according to different deformation amounts, and then the samples are heat-treated.

[0016] The further technical solution is as follows: In the upsetting forging step: the billet size is Φ230×269mm; the billet is heated to the forging temperature of 1080-1100℃; then it is upset and punched to Φ440×Φ180±5×75±5mm; the final forging temperature is 950℃; then it is air cooled to room temperature.

[0017] A further technical solution is as follows: In the hole expansion forging step: the billet is heated to the forging temperature; then the hole is expanded to Φ468×Φ240±5×70±5mm; the hole expansion deformation of the billet is the forging deformation; the final forging temperature is 950℃; then it is air-cooled to room temperature.

[0018] A further technical solution is as follows: In the final rolling and forging step: the billet is heated to the forging temperature; then rolled to Φ502±5×Φ300±5×70±5mm; the billet rolling deformation is the same as the forging deformation; the final forging temperature is ≥950℃; then air-cooled to room temperature to form the product.

[0019] A further technical solution is as follows: In the upsetting and punching step, the processing procedure for upsetting and punching is determined based on the total deformation, the punching diameter, and the billet diameter.

[0020] First processing step: Upsetting the billet;

[0021]

[0022] The nth processing step: upsetting the billet;

[0023] Upsetting or punching processes are performed in each of the first to nth processing stages.

[0024] A further technical solution is to add a heating process every time the billet temperature drops by 10-15% during the upsetting and punching process.

[0025] Compared with the prior art, the beneficial technical effects of the present invention are as follows: (1) By conducting sampling experiments through orthogonal experimental steps, reasonable forging temperature and deformation amount are obtained. The forging temperature and deformation amount values ​​obtained in the subsequent hole expansion forging step and final rolling forging step are applied, so that the forging temperature is higher than the solution temperature, which promotes metal dislocation slip and climb, increases the activation energy of metal atoms, and has a significant dynamic recrystallization effect. At the same time, the tonnage of the equipment is reduced, effectively reducing the possibility of crack generation and ensuring the uniformity of the structure. At the same time, the deformation amount is also increased, which promotes the dynamic recrystallization of the billet and reduces the number of forging fires; (2) In order to eliminate the influence of the sampling process on the sample or specimen, if the sample or specimen has sharp corners, it needs to be rounded. This prevents the sample or specimen from cracking during the sampling process, thereby affecting the test results; (3) By preheating the forging furnace, the heating time of the billet is shortened. By heating the billet to 900°C in a short time, the billet can complete the heating in a short time. By slowly heating the billet to 500℃ and 1080-1100℃ respectively, the billet can be heated evenly in these two stages, resulting in uniform temperature distribution inside and outside the billet and consistent billet structure. Attached Figure Description

[0026] Figure 1 A flowchart of a method for manufacturing a nickel-based alloy casing according to an embodiment of the present invention is shown. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this invention clearer, the device proposed by this invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The advantages and features of this invention will become clearer from the following description. It should be noted that the drawings are in a very simplified form and use non-precise proportions, only for the purpose of conveniently and clearly illustrating the embodiments of this invention. Please refer to the accompanying drawings to make the objectives, features, and advantages of this invention more apparent and understandable. It should be understood that the structures, proportions, sizes, etc., depicted in the accompanying drawings are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the implementation conditions of this invention. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportional relationships, or adjustments to the size, without affecting the effects and objectives achieved by this invention, should still fall within the scope of the technical content disclosed in this invention.

[0028] Figure 1 A flowchart of a method for manufacturing a nickel-based alloy casing according to an embodiment of the present invention is shown. (In conjunction with...) Figure 1As shown, this invention discloses a method for manufacturing a nickel-based alloy casing.

[0029] A method for manufacturing a nickel-based alloy casing includes the following steps:

[0030] Orthogonal experimental procedure: Samples are taken sequentially along the edge of the billet, and then sequentially from the edge towards the center. The samples are heated and held at that temperature, then dissolved and the grain size is measured. The forging temperature is determined by the sample grain size.

[0031] Samples are cut from the billet, and after upsetting and heat-treating the samples according to different deformation amounts, the grain size of the samples is measured. The forging deformation amount is determined by the grain size of the samples.

[0032] Upsetting and punching process: Heat the billet to the forging temperature, then upset and punch. The final forging temperature is 950℃. Afterwards, air cool to room temperature.

[0033] Hole-expanding forging steps: Heat the billet to the forging temperature, then expand the hole. The deformation amount of the billet during hole expansion is the same as the forging deformation amount. The final forging temperature is 950℃. Then air cool to room temperature.

[0034] Final rolling forging steps: The billet is heated to the forging temperature and then rolled. The rolling deformation of the billet is the same as the forging deformation. The final forging temperature is ≥950℃. It is then air-cooled to room temperature to form the product.

[0035] In the orthogonal experimental procedure, several samples are first taken sequentially along the edge of the billet, and then several samples are taken sequentially from the edge of the billet towards the center. The samples are marked for easy experimental recording.

[0036] In the orthogonal experimental procedure: the samples are divided into several groups according to the holding time. Several samples in a single group are heated at different temperatures.

[0037] Several samples were taken sequentially along the edge of the billet and labeled A-1 to A-12. Several more samples were taken sequentially from the edge of the billet towards the center and labeled A-13 and A-14. The test surfaces of samples A-1 to A-14 were marked. Samples A-1 to A-14 were grouped according to Table 1 and subjected to heating and heat preservation. After heating, heat preservation, and solution treatment, the grain size of the samples was measured on the test surfaces.

[0038] In the orthogonal experimental procedure: the samples are divided into several groups according to the heating temperature. Several samples in a single group are forged with different deformation amounts, and then the samples are heat-treated.

[0039] Several samples were taken from the billet, with the sampling locations evenly distributed. These samples were labeled B-1 to B-12. Samples B-1 to B-12 were grouped according to Table 2 and subjected to heating, upsetting, and heat treatment. After heat treatment, samples were taken from the core of the samples to determine the grain size.

[0040] The orthogonal experiments in Tables 1 and 2 show that the billet has the best microstructure when the deformation is between 8-15% within the temperature range of 1055℃ to 1065℃.

[0041] Compared to traditional forging temperatures, which are typically at or below the solution treatment temperature, the purpose is to prevent excessive growth of grains, making it difficult for dislocations to move and thus increasing deformation resistance. Because of the lower forging temperature, the amount of deformation is correspondingly lower.

[0042] Sampling experiments were conducted using an orthogonal experimental procedure to obtain reasonable forging temperature and deformation amount. The obtained forging temperature and deformation amount values ​​were applied in subsequent reaming and final rolling forging steps, ensuring that the forging temperature was higher than the solution treatment temperature. This promoted dislocation slip and climb in the metal, increased the activation energy of metal atoms, and significantly improved dynamic recrystallization. Simultaneously, the tonnage of the equipment was reduced, effectively decreasing the possibility of crack formation and ensuring the uniformity of the microstructure. Furthermore, the increased deformation amount promoted dynamic recrystallization of the billet and reduced the number of forging passes.

[0043]

[0044] Table 1

[0045]

[0046]

[0047] Table 2

[0048] In the orthogonal experimental procedure: the sampling area density along the sampling path is 10-15%. The sampling shape is a mimicry of the product shape. The edges of the sampling shape are rounded.

[0049] To ensure consistency between the sampling test and the billet, the sampling area needs to account for 10-15% of the billet area.

[0050] To eliminate the influence of the sampling process on the sample or specimen, any sharp edges or corners of the sample or specimen should be rounded off. This prevents cracks from forming in the sample or specimen during sampling, which could affect the test results.

[0051] In the upsetting forging process: the billet size is Φ230×269mm. The billet is heated to the forging temperature of 1080-1100℃. Then, it is upset and punched to Φ440×Φ180±5×75±5mm. The final forging temperature is 950℃. Afterward, it is air-cooled to room temperature.

[0052] In the upsetting forging process, the forging furnace is first preheated to 350°C, and then the billet is added for 1 hour of preheating. The furnace is then slowly heated to 500°C for 1.5 hours. Next, the furnace is rapidly heated to 900°C for 1 hour. Finally, the furnace is slowly heated to 1080-1100°C for 2 hours.

[0053] By preheating the forging furnace, the heating time of the billet is shortened. By heating the billet to 900℃ in a short time, the billet can complete the heating process in a shorter period of time. By slowly heating the billet to 500℃ and 1080-1100℃ respectively, the billet can be heated evenly in these two stages, resulting in a uniform temperature distribution inside and outside the billet and a consistent billet microstructure.

[0054] In the reaming forging process: the billet is heated to the forging temperature. Then, the hole is reamed to Φ468×Φ240±5×70±5mm. The reaming deformation of the billet is the same as the forging deformation. The final forging temperature is 950℃. Afterward, it is air-cooled to room temperature.

[0055] In the final rolling and forging step: the billet is heated to the forging temperature. It is then rolled to Φ502±5×Φ300±5×70±5mm. The rolling deformation of the billet is the same as the forging deformation. The final forging temperature is ≥950℃. It is then air-cooled to room temperature to form the product.

[0056] The upsetting forging process involves significant deformation of the billet, and it serves to achieve the basic shaping of the billet. Therefore, the deformation amount and forging temperature obtained in the upsetting process are not applicable to those obtained in the orthogonal experimental procedure.

[0057] The hole-expanding forging step and the final rolling forging step involve expanding the hole and rolling the billet, which have requirements on the amount of deformation and the forging temperature.

[0058] There is a negative correlation between the deformation amount in the hole-expanding forging step and the final rolling forging step. When the deformation amount in the hole-expanding forging step is large, the deformation amount in the final rolling forging step is small. Conversely, when the deformation amount in the hole-expanding forging step is small, the deformation amount in the final rolling forging step is large.

[0059] In both the reaming and final rolling forging steps, the forging temperature and the amount of deformation are positively correlated. When the deformation is large, the forging temperature increases accordingly. When the deformation is small, the forging temperature decreases accordingly.

[0060] In the reaming forging step: the billet is heated to the forging temperature of 1055-1065℃. Then, the hole is reamed to Φ468×Φ240±5×70±5mm. The reaming deformation of the billet is 8-15% of the forging deformation. The final forging temperature is 950℃. Afterward, it is air-cooled to room temperature.

[0061] In the final rolling forging step: the billet is heated to a forging temperature of 1055-1065℃. It is then rolled to Φ502±5×Φ300±5×70±5mm. The rolling deformation is 8-15% of the forging deformation. The final forging temperature is ≥950℃. Afterwards, it is air-cooled to room temperature to form the product.

[0062] The upsetting and punching process is determined based on the total deformation, punching diameter, and billet diameter.

[0063] First processing step: Upsetting the billet.

[0064]

[0065] The nth processing step: upsetting the billet.

[0066] Upsetting or punching processes are performed in each of the first to nth processing stages.

[0067] In the upsetting and punching process, the blank is not upset and punched from Φ230×269mm to Φ440×Φ180±5×75±5mm in one go. It requires repeated upsetting and punching to achieve the required size.

[0068] The upsetting and punching process consists of multiple processing steps, with the first and last steps both involving upsetting. Between the first and last processing steps, upsetting and punching are combined. The combination is determined by the total deformation of the billet during the upsetting and punching steps, the diameter of the punched hole, and the diameter of the billet.

[0069] The number of machining operations is determined by the total deformation of the billet during the upsetting and punching process. The greater the total deformation of the billet during the upsetting and punching process, the more machining operations are required.

[0070] The number of punching operations is determined by the diameter of the blank's hole in the upsetting and punching process. The larger the diameter of the blank's hole in the upsetting and punching process, the more punching operations are required.

[0071] The number of upsetting operations is determined by the diameter of the blank in the upsetting and punching process. The larger the diameter of the blank in the upsetting and punching process, the more upsetting operations are required.

[0072] During the upsetting and punching process, a heating process is added every time the billet temperature drops by 10-15%.

[0073] When the upsetting and punching process is repeated many times, the temperature of the billet will drop during the processing. If the temperature is too low, it will affect the quality of the upsetting and punching and cause transgranular cracks.

[0074] When the billet temperature drops below 1080-1100℃ by 10-15%, it needs to be heated back to 1080-1100℃. When the billet temperature drops below 1080-1100℃ again by 10-15%, the above steps are repeated.

[0075] In the upsetting forging process: the billet size is Φ230×269mm. The billet is heated to the forging temperature of 1080-1100℃.

[0076] The upsetting and punching process is determined based on the total deformation, punching diameter, and billet diameter.

[0077] First processing step: Upsetting the billet.

[0078] The second processing step: punching holes in the blank.

[0079] The third processing step: upsetting the billet.

[0080] Heating process: Heat the billet to the forging temperature: 1080-1100℃.

[0081] The fourth processing step: punching holes in the blank.

[0082] Fifth processing step: Upsetting the billet to Φ440×Φ180±5×75±5mm.

[0083] The final forging temperature was 950℃. It was then air-cooled to room temperature.

[0084] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0085] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A method for manufacturing a nickel-based alloy casing, characterized in that: Includes the following steps: Orthogonal experimental procedure: Sample along the edge of the billet in sequence, and then sample from the edge to the center in sequence; the sampling area density in the sampling path is 10%-15%; the corners of the sampling shape are rounded. The samples were divided into several groups according to the holding time. Several samples in each group were heated at different temperatures. Several samples were taken along the edge of the billet and marked as A-1 to A-12 respectively. Several samples were taken from the edge of the billet toward the center and marked as A-13 and A-14 respectively. The test surfaces of samples A-1 to A-14 were marked. The samples were then heated and held at the temperature. The heating range for sample A1 is 1015℃ ≤ temperature < 1025℃; the heating range for sample A2 is 1025℃ ≤ temperature < 1035℃; the heating range for sample A3 is 1035℃ ≤ temperature < 1045℃; the heating range for sample A4 is 1045℃ ≤ temperature < 1055℃; the heating range for sample A5 is 1055℃ ≤ temperature < 1065℃; the heating range for sample A6 is 1065℃ ≤ temperature < 1075℃; the holding time for samples A1-A6 is 1.5h. The heating range for sample A7 is 1015℃ ≤ temperature < 1025℃; the heating range for sample A8 is 1025℃ ≤ temperature < 1035℃; the heating range for sample A9 is 1035℃ ≤ temperature < 1045℃; the heating range for sample A10 is 1045℃ ≤ temperature < 1055℃; the heating range for sample A11 is 1055℃ ≤ temperature < 1065℃; the heating range for sample A12 is 1065℃ ≤ temperature < 1075℃; the heating range for sample A13 is 1015℃ ≤ temperature < 1025℃; the heating range for sample A14 is 1015℃ ≤ temperature < 1025℃; the holding time for samples A7 to A14 is 3 hours. After heat preservation, the samples were solution-treated. The solution-treatment heating range for samples A1-A14 was 996℃≤solution℃≤1030℃. After solution treatment, the grain size of the sample is measured on the test surface, and the forging temperature is determined by the grain size of the sample. Samples were cut and evenly distributed for upsetting under heat. The samples were divided into several groups according to the heating temperature, labeled B1-B12. Within each group, several samples were upset with different deformation amounts. The first group consisted of samples B1-B4, heated to 1045℃, with deformation amounts of 2% for B1, 6% for B2, 11% for B3, and 16% for B4. The second group consisted of samples B5-B8, heated to 1055℃, with deformation amounts of 3% for B5, 8% for B6, 12% for B7, and 18% for B8. The third group consisted of samples B9-B12, heated to 1065℃, with deformation amounts of 5% for B9, 10% for B10, 15% for B11, and 20% for B12. The samples were heat-treated: solution treatment at 1030℃ and aging at 843℃. After heat treatment, samples were taken from the core of the samples to test the grain size, and the forging deformation was determined by the grain size. Through orthogonal experiments, it was found that the deformation was between 8% and 15% in the forging temperature range of 1055℃ ≤ temperature < 1065℃. Upsetting and punching steps: Heat the billet to the forging temperature, then perform upsetting and punching; the final forging temperature is 950℃; then air cool to room temperature; In the upsetting and punching process: the billet size is Φ230×269mm; the forging furnace is preheated first, and after the forging furnace is rapidly preheated to 350℃, the billet is added and the preheating time is 1 hour; then the forging furnace is slowly heated to 500℃ for 1.5 hours; then the forging furnace is rapidly heated to 900℃ for 1 hour; finally, the forging furnace is slowly heated to 1080℃-1100℃ for 2 hours. Then, the hole is upset and punched to Φ440×Φ180±5×75±5mm; the final forging temperature is 950℃; then it is air-cooled to room temperature. Hole reaming forging steps: Heat the billet to the forging temperature; then ream the hole to Φ468×Φ240±5×70±5mm; the hole reaming deformation of the billet is the forging deformation; the final forging temperature is 950℃; then air cool to room temperature; Final rolling forging steps: Heat the billet to the forging temperature; then roll it to Φ502±5×Φ300±5×70±5mm; the rolling deformation of the billet is the forging deformation; the final forging temperature is ≥950℃; then air cool to room temperature to form the product; During the upsetting and punching process, a heating process is added every time the billet temperature drops by 10-15%.

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