Partial additive billet manufacturing and zoned die forging method and system for superalloy disk forgings

Abstract

The application belongs to the technical field of forming manufacturing of high-temperature alloy disc-shaped forgings, and discloses a local additive billet manufacturing and zoned die forging method and system for high-temperature alloy disc-shaped forgings, which comprises the following steps: according to the structural complexity of different regions of the high-temperature alloy disc-shaped forging, the pre-billet is divided into a base blank and additive billets; the additive billets are locally manufactured on the base blank to obtain the pre-billet; the pre-billet is heat treated to obtain a forging blank; according to the deformation amount and the dynamic recrystallization fraction of different regions of the forging blank, the small deformation zone of the forging blank is determined; the forging blank is subjected to zoned die forging to obtain the high-temperature alloy disc-shaped forging. The zoned die forging method is adopted to actively control the deformation amount of different regions, to control the uniformity of the structure in different regions, to realize the customized forming of the structure state and performance of different regions, and to obtain the high-temperature alloy disc-shaped forging with more excellent performance.

Description

Technical Field

[0001] This invention belongs to the field of high-temperature alloy disc forging technology, and particularly relates to a method and system for local additive manufacturing and partitioned die forging of high-temperature alloy disc forgings. Background Technology

[0002] High-temperature alloys possess excellent high-temperature strength, good corrosion resistance, and oxidation resistance, and are widely used in the manufacture of key hot-end components in high-end equipment such as aero engines and gas turbines.

[0003] High-temperature alloy disc forgings operate under extreme conditions such as high temperature, high pressure, high speed, and variable load for extended periods, resulting in varying performance requirements across different regions. The central region of the disc forging operates at a relatively low temperature but must withstand significant centrifugal force, necessitating high yield strength and low-cycle fatigue performance. The edge regions, exposed to high-temperature gases (reaching temperatures exceeding 840°C), require excellent creep resistance, anti-crack properties, and resistance to fatigue crack propagation. This difference in performance requirements between the central and edge regions implies different target microstructure requirements for the final forging. The central region requires a predominantly fine-grained microstructure, while the edge region leans towards coarse-grained or columnar grains. However, achieving customized target microstructures using existing die forging methods is challenging.

[0004] Existing die forging processes require pre-forming a billet according to the forging shape before die forging to minimize deformation dead zones and obtain a suitable billet shape. For complex-shaped forgings, pre-forming in multiple stages is also necessary, leading to longer production cycles and higher costs. This process also easily causes grain growth in the deformed structure, reducing microstructure uniformity. After die forging, dissection of the final forging reveals minimal deformation in the central region, while cold-die structures are present in the edge regions. Local microstructure uniformity is poor, with significant grain size variations exceeding tolerances, making it difficult to control within level 2. This severely impacts the service performance of high-temperature alloy disc forgings.

[0005] It is evident that high-temperature alloy disc forgings formed using existing die forging processes suffer from challenges such as the difficulty in achieving customized forming of microstructures in different regions and the difficulty in controlling the uniformity of microstructure in different areas. Therefore, there is an urgent need to design a new forming method to overcome these problems. Summary of the Invention

[0006] To address the problems existing in the prior art, this invention provides a method and system for local additive manufacturing and partitioned die forging of high-temperature alloy disc forgings.

[0007] This invention employs additive manufacturing for partial blanking, adding material to a simple blank to create a highly complex local structure, simplifying the blanking process, reducing production costs, and producing an ideal shape blank suitable for zonal die forging. This reduces the difficulty of controlling the uniformity of the microstructure during subsequent die forging. By using a zonal die forging method, the deformation amount in different regions is actively controlled, and the uniformity of the microstructure is zonal, enabling customized forming of the microstructure and properties in different regions, resulting in high-temperature alloy disc forgings with superior performance.

[0008] This invention is achieved through a method for partial additive manufacturing and zoned die forging of high-temperature alloy disc-shaped forgings, comprising the following steps:

[0009] S1: Based on the billet-making difficulty of different areas of high-temperature alloy disc forgings, precast billets are divided into base billets and additive billets;

[0010] S2: Locally additively manufacture additive billets on a base blank to obtain preformed billets;

[0011] S3: Heat-treat the precast billet to obtain a forged billet;

[0012] S4: Determine the small deformation zone of the forging blank based on the deformation amount and dynamic recrystallization fraction in different regions of the forging blank;

[0013] S5: Perform zoned die forging on the forging billet to obtain high-temperature alloy disc-shaped forgings.

[0014] Furthermore, in S1, the base blank is a forging region with low structural complexity that can be formed in one blanking process, while the additive blank is a forging region with high structural complexity that is difficult to form in one blanking process.

[0015] Furthermore, in step S2, the surface of the substrate blank is polished and cleaned; the additive material is the same as that of the substrate blank; the additive current is 50-300A, the additive voltage is 5-40V, the wire feeding speed is 0.1-20m / min, the additive speed is 0.1-10m / min, the protective gas is an atmosphere of argon mixed with 0-40% carbon dioxide, the gas flow rate is 5-30L / min, and the interlayer cooling is 0-30min.

[0016] Furthermore, in step S3, the heat treatment includes: homogenizing the preform at a temperature of 900–1200°C for 0.1–5 h and cooling it with water; and aging the homogenized preform at a temperature of 800–1000°C for 0.5–48 h and cooling it with air.

[0017] Furthermore, in S4, the small deformation zone is set as the forging billet region with a deformation amount of 0-40% and / or a dynamic recrystallization fraction of 0-50%.

[0018] Furthermore, in S5, the partitioned die forging includes: machining the surface of the forging billet until it is bright; heating the machined forging billet to the forming temperature and holding it at that temperature; preheating the die; pre-forging the small deformation zone of the forging billet by placing a backing plate under the inner lower die, placing the heated forging billet on the lower die, and pressing down the upper die to complete the pre-forging of the small deformation zone of the forging billet; and performing overall die forging of the forging billet by removing the backing plate, adjusting the positions of the outer lower die and the inner lower die, and pressing down the upper die to obtain a high-temperature alloy disc forging.

[0019] Another object of the present invention is to provide a system for local additive manufacturing and partitioned die forging of high-temperature alloy disc forgings, which implements the aforementioned method of local additive manufacturing and partitioned die forging of high-temperature alloy disc forgings, the system comprising:

[0020] The billet division module divides precast billets into base billets and additive billets based on the structural complexity of different areas of high-temperature alloy disc forgings.

[0021] The precast billet manufacturing module is connected to the billet dividing module. It locally additively manufactures additive billets on the base blank to obtain precast billets.

[0022] The heat treatment module is connected to the precast billet manufacturing module to perform heat treatment on the precast billet to obtain a forging billet;

[0023] The small deformation zone determination module is connected to the heat treatment module. It determines the small deformation zone of the forging billet based on the deformation amount and dynamic recrystallization fraction of different regions of the forging billet.

[0024] The partitioned die forging module, connected to the small deformation zone determination module, performs partitioned die forging on the forging billet to obtain high-temperature alloy disc-shaped forgings.

[0025] Another object of the present invention is to provide a computer device, characterized in that the computer device includes a memory and a processor, the memory storing a computer program, and when the computer program is executed by the processor, causing the processor to perform the steps of the partial additive blanking and partitioned die forging method for the high-temperature alloy disc forging.

[0026] Another object of the present invention is to provide a computer-readable storage medium storing a computer program, which, when executed by a processor, causes the processor to perform the steps of the partial additive blanking and partitioned die forging method for the high-temperature alloy disc forging.

[0027] Another objective of this invention is to provide an information data processing terminal, which is used to realize the local additive manufacturing and zoned die forging system of the high-temperature alloy disc forging.

[0028] Another object of the present invention is to provide a system for handling electromagnetic leakage interference from an electromagnetic vibration table, characterized in that the system comprises:

[0029] The signal acquisition and analysis module is used to monitor the electromagnetic signals generated by the electromagnetic vibration table in real time during operation and to identify the interference frequency range.

[0030] The filter selection and design module automatically selects or designs suitable filters based on the frequency range identified by the signal acquisition and analysis module.

[0031] The filtering unit is used to install filters on necessary power lines and signal lines to perform interference suppression measures;

[0032] The testing and optimization module is used to evaluate the filtering effect and adjust the filter configuration as needed to optimize the electromagnetic interference suppression effect.

[0033] The monitoring and adjustment module is used to continuously monitor the electromagnetic signals of the electromagnetic vibration table and adaptively adjust the filter configuration according to changes in the experimental environment to ensure long-term effective electromagnetic interference control.

[0034] Another object of the present invention is to provide an electromagnetic leakage interference handling system for an electromagnetic vibration table, the system comprising:

[0035] A signal acquisition device is used to acquire electromagnetic signals generated by an electromagnetic vibration table in real time during operation.

[0036] An analysis module, connected to the signal acquisition device, is used to analyze the acquired electromagnetic signals and identify the interference frequency range;

[0037] A filter library containing various types of filters;

[0038] A filter selection module automatically selects a suitable filter from the filter library based on the interference frequency range identified by the analysis module.

[0039] It also includes a filtering module for installing selected filters on the power and signal lines of the electromagnetic vibration table to suppress electromagnetic interference.

[0040] Another object of the present invention is to provide an adaptive control system for handling electromagnetic leakage interference in an electromagnetic vibration table, comprising:

[0041] A real-time signal monitoring unit is used to monitor the electromagnetic signal output of the electromagnetic vibration table in real time.

[0042] A frequency analysis unit, connected to a real-time signal monitoring unit, is used to analyze the frequency characteristics of electromagnetic signals and determine the interference frequency range;

[0043] An adaptive filter configuration module automatically configures or adjusts the filter parameters based on the interference frequency range determined by the frequency analysis unit.

[0044] The system also includes a filtering unit for applying configured filters to the power and signal lines of the electromagnetic vibration table to effectively control electromagnetic leakage interference. Furthermore, the system incorporates a feedback adjustment mechanism to adjust the filter configuration in real time based on the operating status of the electromagnetic vibration table and changes in the electromagnetic signals, thereby maintaining long-term effective control of electromagnetic interference.

[0045] Based on the above technical solutions and the technical problems solved, please analyze the advantages and positive effects of the technical solution to be protected by this invention from the following aspects:

[0046] First, existing die forging processes require pre-forming the blank according to the forging shape before die forging. For complex-shaped forgings, pre-forming requires multiple heat treatments, leading to long production cycles and high costs. This also easily causes grain growth in the deformed structure, reducing microstructure uniformity. After die forging, the deformation in the central region of the final forging is small, while the edge region exhibits cold die structure. The deformation varies significantly across different regions, resulting in poor local microstructure uniformity and severely excessive grain size differences, making it difficult to control within level 2. This seriously affects the service performance of high-temperature alloy disc forgings. This invention employs local additive manufacturing forging and zoned die forging to control the microstructure uniformity of high-temperature alloy disc forgings. This invention utilizes additive manufacturing for local forging, overcoming the process constraints on blank shape imposed by existing forging methods. This greatly reduces the difficulty of forging, significantly reduces the number of heat treatments, shortens the production cycle, and produces ideal-shaped blanks suitable for zoned die forging, thus helping to improve the microstructure uniformity of high-temperature alloy disc forgings. This invention employs zoned die forging, which can actively control the material rheological behavior of local areas in high-temperature alloy disc forgings, precisely increase the deformation of difficult-to-form and target areas, customize and control the target microstructure of each area of ​​the high-temperature alloy disc forgings, improve the microstructure uniformity, and obtain high-temperature alloy disc forgings with superior performance.

[0047] Secondly, this invention effectively solves the problems of complex billet preparation processes, long manufacturing cycles, difficulty in achieving customized forming of microstructures in different regions, and difficulty in controlling microstructure uniformity in different areas of high-temperature alloy disc forgings formed by existing die forging processes. It employs additive manufacturing for localized billet preparation, adding material to a simple blank to create highly complex local structures, simplifying the billet preparation process and shortening the production cycle. By using a zoned die forging method, the deformation amount in different regions is actively controlled, and the microstructure uniformity is controlled in different zones, achieving customized forming of the microstructure and properties in different regions, resulting in high-temperature alloy disc forgings with superior performance.

[0048] Improved manufacturing efficiency and economy: This invention significantly improves the manufacturing efficiency and economy of high-temperature alloy disc forgings and reduces production costs through local additive manufacturing and zoned die forging methods.

[0049] Comprehensive optimization of forging performance: By precisely controlling the forging process and heat treatment, this invention not only improves the geometric accuracy of forgings, but also optimizes their mechanical properties and microstructure, ensuring the high performance and reliability of high-temperature alloy disc forgings.

[0050] Innovation in process and expansion of application: The technical solution of this invention provides a new process path in the manufacturing of high-temperature alloy disc forgings, and also has important reference value and application potential for the forging and manufacturing of other high-performance alloy materials.

[0051] Third, the technical solution of this invention solves a technical problem that people have long desired to solve but have been unable to achieve successfully, as described in detail below:

[0052] Existing die forging processes require multiple pre-forming stages, resulting in complex billet preparation, long production cycles, and high manufacturing costs. They also easily lead to grain growth in the deformed structure, reducing microstructure uniformity. After die forging, significant differences in deformation amount exist in different regions, leading to poor local microstructure uniformity and severe grain size variations, which seriously affect the service performance of high-temperature alloy disc forgings. This invention employs additive manufacturing for localized billet preparation, adding complex local structures to a simple blank, simplifying the billet preparation process, shortening the production cycle, and reducing the impact on grain structure. By using a zoned die forging method, the deformation amount in different regions is actively controlled, and the microstructure uniformity is adjusted in different zones, achieving customized forming of the microstructure and properties of different regions, resulting in high-temperature alloy disc forgings with superior performance.

[0053] Fourth, the significant technological advancements demonstrated by the method provided by this invention in handling electromagnetic leakage interference from electromagnetic vibration tables are mainly reflected in the following aspects:

[0054] 1. Real-time monitoring and frequency identification technology: By activating the signal acquisition and analysis module, this method can monitor the electromagnetic signals generated by the electromagnetic vibration table during operation in real time and accurately identify the interference frequency range. The introduction of this real-time monitoring and frequency identification technology greatly improves the accuracy and timeliness of electromagnetic interference processing, providing reliable data support for subsequent filter selection and design.

[0055] 2. Intelligent Filter Selection and Design: Based on the identified frequency range, this method can automatically select or design suitable filters through a filter selection and design module. This intelligent filter selection and design approach avoids the shortcomings of traditional methods that rely on human experience and trial and error, thus improving filter matching and filtering performance.

[0056] 3. Precision and Flexibility of Filtering: By utilizing a filtering unit and installing filters on necessary power and signal lines, interference suppression measures are implemented. This method not only ensures the precision of filtering but also offers high flexibility, allowing for the selection of appropriate filtering methods based on different interference frequency ranges to achieve optimal electromagnetic interference suppression.

[0057] 4. Effect Evaluation and Optimization: By running the testing and optimization modules, this method can evaluate the filtering effect and adjust the filter configuration as needed to optimize the electromagnetic interference suppression effect. This closed-loop optimization mechanism enables the electromagnetic interference treatment method to be continuously improved and adapted to different experimental environments and changing requirements.

[0058] 5. Long-term monitoring and adaptive adjustment: The monitoring and adjustment module continuously executes to adapt to changes in the experimental environment, ensuring long-term effective electromagnetic interference control. This long-term monitoring and adaptive adjustment capability enables the method to cope with various changes in the experimental environment and maintain the stability and effectiveness of electromagnetic interference control.

[0059] The method provided by this invention significantly improves the effectiveness and efficiency of handling electromagnetic leakage interference from electromagnetic vibration tables by introducing real-time monitoring and frequency identification technology, intelligent filter selection and design, precise filtering processing, effect evaluation and optimization, and long-term monitoring and adaptive adjustment, bringing important technological progress to the field of electromagnetic interference control. Attached Figure Description

[0060] Figure 1 This is a schematic flowchart of the method for partial additive manufacturing and zoned die forging of high-temperature alloy disc forgings involved in this invention.

[0061] Figure 2 This is a schematic diagram of a high-temperature alloy disc-shaped forging manufactured in a specific embodiment of the present invention;

[0062] Figure 3 This is a schematic diagram of a preformed billet produced by partial additive manufacturing in a specific embodiment of the present invention;

[0063] Figure 4 This is a schematic diagram of the pre-forging of the small deformation zone of the forging billet in a specific embodiment of the present invention;

[0064] Figure 5 This is a schematic diagram of the integral die forging forming of the forging billet in a specific embodiment of the present invention;

[0065] Figure 6 This is a microstructure diagram of the hub region of a high-temperature alloy disc forging manufactured in a specific embodiment of the present invention;

[0066] Figure 7This is a microstructure diagram of the rim region of a high-temperature alloy disc-shaped forging manufactured in a specific embodiment of the present invention;

[0067] Figure 8 This is a structural diagram of the partial additive manufacturing and zoned die forging system for high-temperature alloy disc forgings involved in this invention;

[0068] Figure 9 This is a microstructure diagram of the hub region of a high-temperature alloy disc forging formed using existing die forging technology in Comparative Example 1 of this invention;

[0069] Figure 10 This is a microstructure diagram of the rim region of a high-temperature alloy disc forging formed using existing die forging technology in Comparative Example 1 of this invention;

[0070] In the diagram: 1. Hub; 2. Flange; 3. Base blank; 4. Additive blank; 5. Upper mold; 6. External lower mold; 7. Internal lower mold; 8. Pad. Detailed Implementation

[0071] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0072] Example 1: Manufacturing of Disc-type Components for Aircraft Engines

[0073] Disc-shaped components of aero engines, such as turbine discs and compressor discs, are critical load-bearing structures with extremely high requirements for performance and reliability. These components are often made of high-temperature alloy materials and have complex geometries and stringent performance requirements.

[0074] Local additive manufacturing: For areas with high structural complexity, such as impeller grooves and other complex geometries, local additive manufacturing technology is used to add material to the base blank to form the required complex shape.

[0075] Partial die forging: The pre-made billet after partial additive manufacturing is heat-treated and pre-processed, and then, according to the deformation characteristics and performance requirements of different areas of the forging, the partial die forging technology is adopted to precisely forge each area.

[0076] Performance optimization: By independently optimizing forging parameters such as temperature, pressure and cooling rate for each zone, the material properties of each zone are ensured to meet design requirements, thereby obtaining high-performance aero-engine disc components.

[0077] Example 2: Manufacturing of Turbine Disks for High-Performance Automotive Turbochargers

[0078] The turbine disks of turbochargers in high-performance cars need to withstand high temperatures, high-speed rotation, and complex load conditions, which places high demands on the performance of materials and manufacturing processes.

[0079] Additive prototyping: For high-stress areas in the turbine disk of a turbocharger, such as the root connection area of ​​the turbine blade, local additive prototyping technology is used to add material at the corresponding position of the base blank to enhance the local performance of the component.

[0080] Partial forging: Precast billets that have undergone partial additive processing and heat treatment are forged using a partial die forging method. In particular, forging parameters are precisely controlled for additive processing parts and key performance areas to achieve optimal material properties.

[0081] Performance customization: Through partitioned die forging technology, the material properties of different functional areas of the turbine disk can be customized, such as improving the fatigue resistance of the blade root and the overall high-temperature performance.

[0082] This invention addresses the following problems and deficiencies in the prior art, achieving significant technological advancements:

[0083] Forming problems in areas with high structural complexity: In the traditional forging process, some areas are difficult to form in one step to achieve the expected geometry and material properties due to their complex shape, high dimensional accuracy requirements or material properties, resulting in low yield and high production costs.

[0084] Limitations on forming accuracy and material utilization: Traditional forging methods often face problems of insufficient forming accuracy and low material utilization when processing complex-shaped high-temperature alloy disc forgings, especially in the critical performance areas of the forgings.

[0085] Difficulties in heat treatment and microstructure control: In the forging process of high-temperature alloys, homogenization heat treatment and aging treatment are crucial for obtaining excellent mechanical properties, but traditional methods have limitations in achieving uniform microstructure and consistent performance of forgings.

[0086] To address the problems existing in the prior art, the technical solution adopted in this invention is: local additive manufacturing: by locally additive manufacturing additive billets on the base blank, this invention can specifically solve the forming problem in areas with high structural complexity, and improve the forming performance and yield of forgings.

[0087] Improved precision forming and material utilization: By adopting a zoned die forging method, the deformation amount and dynamic recrystallization fraction of different areas of the forging billet are precisely controlled, which improves the forming accuracy and material utilization of the forging.

[0088] Heat treatment and microstructure optimization: By homogenizing and aging the preform, this invention optimizes the heat treatment process of forgings, thereby achieving uniformity of microstructure and improvement of overall performance of forgings.

[0089] This invention provides a method for partial additive manufacturing and zoned die forging of high-temperature alloy disc-shaped forgings. For detailed procedures, please refer to [link to relevant documentation]. Figure 1 This includes the following steps:

[0090] S1: Based on the structural complexity of different areas of high-temperature alloy disc forgings, precast billets are divided into base blanks and additive blanks;

[0091] S2: Locally additively manufacture additive billets on a base blank to obtain preformed billets;

[0092] S3: Heat-treat the precast billet to obtain a forged billet;

[0093] S4: Determine the small deformation zone of the forging blank based on the deformation amount and dynamic recrystallization fraction in different regions of the forging blank;

[0094] S5: Perform zoned die forging on the forging billet to obtain high-temperature alloy disc-shaped forgings.

[0095] In a specific embodiment, in S1, the base blank is a forging region with low structural complexity that can be formed in one blanking process, while the additive blank is a forging region with high structural complexity that is difficult to form in one blanking process.

[0096] In a specific embodiment, in S2, the surface of the substrate blank is polished and cleaned; the additive material is the same as that of the substrate blank; the additive current is 50-300A, the additive voltage is 5-40V, the wire feeding speed is 0.1-20m / min, the additive speed is 0.1-10m / min, the protective gas is an atmosphere of argon mixed with 0-40% carbon dioxide, the gas flow rate is 5-30L / min, and the interlayer cooling is 0-30min.

[0097] In a specific embodiment, in S3, the heat treatment includes: homogenizing the preform at a temperature of 900–1200°C for 0.1–5 h and cooling it with water; and aging the homogenized preform at a temperature of 800–1000°C for 0.5–48 h and cooling it with air.

[0098] In a specific embodiment, in S4, the small deformation zone is set as the forging billet area with a deformation amount of 0-40% and / or a dynamic recrystallization fraction of 0-50%.

[0099] In a specific embodiment, S5, the partitioned forging includes: machining the surface of the forging billet until it is bright; heating the machined forging billet to the forming temperature and holding it at that temperature; preheating the die; pre-forging the small deformation zone of the forging billet by placing a backing plate under the inner lower die, placing the heated forging billet on the lower die, and pressing down the upper die to complete the pre-forging of the small deformation zone of the forging billet; performing overall forging of the forging billet by removing the backing plate, adjusting the positions of the outer lower die and the inner lower die, and pressing down the upper die to obtain a high-temperature alloy disc forging.

[0100] The target high-temperature alloy disc forging is a GH4169 alloy disc forging with an outer diameter of 800mm and a height of 240mm, including a hub 1 and a rim 2. Figure 2 The wheel hub area and the rim area have a large difference in wall thickness. Using traditional die forging process, it is easy to cause deformation dead zone in the hub area and cold die structure in the rim area. The grain size difference is serious and the structure is not uniform.

[0101] This embodiment uses local additive manufacturing and zoned die forging methods to control the uniformity of the microstructure. The process is as follows:

[0102] S1: Based on the structural complexity of different areas of high-temperature alloy disc forgings, precast billets are divided into base blanks and additive blanks;

[0103] Specifically, Figure 2 The hub area of ​​the high-temperature alloy disc forging shown has low structural complexity, and the hub area is used as the base blank. Figure 2 The rim region of the high-temperature alloy disc forging shown has a highly complex structure, making it difficult to form in a single blank. Therefore, the rim region is used as an additive blank. A schematic diagram of the preform is shown below. Figure 3 As shown.

[0104] S2: Locally additively manufacture additive billets on a base blank to obtain preformed billets;

[0105] Specifically, the base blank material is GH4169 alloy, with the following main chemical composition: Ni 52.91%, Cr 19.01%, Nb 4.75%, Mo 2.80%, Al 0.20%, Ti 0.97%, C 0.05%, Si 0.10%, and the balance being Fe. The chemical composition is expressed in wt.%. The surface of the base blank is polished with an angle grinder to remove the oxide layer, and acetone is used to clean away oil stains. The base blank is then fixed on the worktable. 1.1mm diameter GH4169 welding wire is used for additive welding. The chemical composition is as follows: Ni 52.91%, Cr 19.01%, Nb 4.75%, Mo 2.80%, Al 0.20%, Ti 0.97%, C 0.05%, Si 0.10%, with the balance being Fe. The unit of chemical composition is wt.%. The additive manufacturing process adopts a cold metal transfer process, with an additive current of 120A, an additive voltage of 18V, a wire feed speed of 4.8m / min, an additive speed of 0.5m / min, and an argon atmosphere as the protective gas with a gas flow rate of 20L / min. The interlayer cooling time is 3min.

[0106] S3: Heat-treat the precast billet to obtain a forged billet;

[0107] Specifically, the heat treatment includes: homogenizing the preform at a temperature of 1080℃ for 2 hours, with water cooling; and aging the homogenized preform at a temperature of 900℃ for 24 hours, with air cooling.

[0108] S4: Determine the small deformation zone of the forging blank based on the deformation amount and dynamic recrystallization fraction in different regions of the forging blank;

[0109] Specifically, the deformation in the forged wheel hub area is less than 40%, and the dynamic recrystallization fraction is less than 50%, thus defining the forged wheel hub area as a small deformation zone.

[0110] S5: Perform zoned die forging on the forging billet to obtain high-temperature alloy disc-shaped forgings.

[0111] Specifically, the surface of the forging billet is machined to a bright finish; the machined forging billet is heated to 1020℃ and held at that temperature; the die includes an upper die 5, an outer lower die 6, an inner lower die 7, and a backing plate 8. The upper die 5 is located at the top, the outer lower die 6 is located below the upper die, and during die forging, the upper die 5 is in contact with the outer lower die 6, the inner lower die 7 is located in the center hole of the outer lower die 6, and the backing plate 8 is located below the inner lower die 7 and in contact with it. The die is preheated to 1020℃; the hub area of ​​the forging billet is pre-forged, the backing plate is placed under the inner lower die, the heated forging billet is placed on the lower die, and the upper die is pressed down at a speed of 2mm / s, with a deformation of 60%, thus completing the pre-forging of the hub area of ​​the forging billet. Figure 4 The forging billet is integrally forged, the backing plate is removed, the positions of the outer and inner lower dies are adjusted, and the upper die is pressed down at a speed of 2 mm / s, with a deformation of 60%, to obtain a high-temperature alloy disc forging. Figure 5 ).

[0112] In the manufacturing process of high-temperature alloy disc forgings, precise control of the die forging process is crucial to achieving the desired shape and dimensions. This process employs a zoned die forging technique, ensuring precise forming of each forging section and good microstructure uniformity through a detailed description of the die structure and usage. The die system consists of an upper die, an outer lower die, an inner lower die, and a backing plate. The upper die, located at the top, is responsible for pressing the forging billet downwards; the outer and inner lower dies work together to form the external structure and internal features of the forging, respectively; the backing plate is used in the pre-forging stage to support and form specific areas.

[0113] First, the hub region is formed through a pre-forging step. In this process, a backing plate is placed below the inner lower die, while the heated forging billet is placed above it. The upper die is pressed down at a rate of 2 mm / s and with 60% deformation, specifically for forming the rim region. This step not only ensures that the hub region is precisely formed according to design requirements but also lays the foundation for controlling the uniformity of the microstructure during subsequent integral forging.

[0114] Next, the forged billet undergoes integral die forging. In this stage, the backing plate is first removed, and then the positions of the outer and inner lower dies are adjusted to accommodate the integral forging requirements. Similarly, the upper die is pressed down at a speed of 2 mm / s, with the deformation maintained at 60%, to ensure that other structural parts, such as the spokes and rims, except for the hub area, are correctly formed. This step is crucial; it ensures that the structure of each part of the forging meets design requirements and exhibits good microstructure uniformity through precise die positioning and pressure control.

[0115] By employing the aforementioned zoned die forging technology and precisely controlled process parameters, the accurate forming of high-temperature alloy disc forgings can be achieved. From the pre-forging of the hub area to the overall die forging, each step is designed to ensure good microstructure uniformity and a structure that closely matches the design drawings. This process not only improves the quality and precision of the finished product but also provides an effective solution for the manufacturing and microstructure control of complex forgings.

[0116] To verify the microstructure uniformity of the high-temperature alloy disc forgings, samples were taken from the hub and rim areas of the forgings for microstructure observation. The microstructure of the hub area is shown in the image below. Figure 6As shown, the grain structure consists of fine equiaxed crystals with an average grain size of 21.3 μm and good uniformity. The microstructure of the rim region is shown in the figure below. Figure 7 As shown, the grain structure is equiaxed with an average grain size of 67.1 μm and exhibits good uniformity.

[0117] like Figure 8 As shown, this embodiment of the invention provides a system for partial additive manufacturing and partitioned die forging of alloy disc forgings, which implements the aforementioned method for partial additive manufacturing and partitioned die forging of high-temperature alloy disc forgings. The system includes:

[0118] The billet division module divides precast billets into base billets and additive billets based on the structural complexity of different areas of high-temperature alloy disc forgings.

[0119] The precast billet manufacturing module is connected to the billet dividing module. It locally additively manufactures additive billets on the base blank to obtain precast billets.

[0120] The heat treatment module is connected to the precast billet manufacturing module to perform heat treatment on the precast billet to obtain a forging billet;

[0121] The small deformation zone determination module is connected to the heat treatment module. It determines the small deformation zone of the forging billet based on the deformation amount and dynamic recrystallization fraction of different regions of the forging billet.

[0122] The partitioned die forging module is connected to the small deformation zone determination module to perform partitioned die forging on the forging billet to obtain high-temperature alloy disc-shaped forgings.

[0123] This invention provides a computer device, characterized in that the computer device includes a memory and a processor, the memory stores a computer program, and when the computer program is executed by the processor, the processor performs the steps of the local additive manufacturing and partitioned die forging method for the high-temperature alloy disc forging.

[0124] This invention provides a computer-readable storage medium storing a computer program, which, when executed by a processor, causes the processor to perform the steps of the partial additive manufacturing and partitioned die forging method for the high-temperature alloy disc forging.

[0125] This invention provides an information data processing terminal, which is used to realize the local additive manufacturing and zoned die forging system of the high-temperature alloy disc forging.

[0126] It should be noted that embodiments of the present invention can be implemented in hardware, software, or a combination of both. The hardware portion can be implemented using dedicated logic; the software portion can be stored in memory and executed by a suitable instruction execution system, such as a microprocessor or dedicated-design hardware. Those skilled in the art will understand that the above-described devices and methods can be implemented using computer-executable instructions and / or included in processor control code, for example, such code provided on a carrier medium such as a disk, CD, or DVD-ROM, a programmable memory such as read-only memory (firmware), or a data carrier such as an optical or electronic signal carrier. The devices and modules of the present invention can be implemented by hardware circuitry such as very large-scale integrated circuits or gate arrays, semiconductors such as logic chips, transistors, or programmable hardware devices such as field-programmable gate arrays, programmable logic devices, etc., or by software executed by various types of processors, or by a combination of the above-described hardware circuitry and software, such as firmware.

[0127] Comparative Example 1

[0128] The target high-temperature alloy disc forging is a GH4169 alloy disc forging with an outer diameter of 800 mm and a height of 240 mm, which is formed using existing die forging processes.

[0129] Specifically, the billet is prepared by multiple hot forging processes to obtain a blank, which is then die-forged at a forming temperature of 1020℃, a pressing rate of 2mm / s, and a deformation of 60%. Samples were taken from the hub and rim areas of the high-temperature alloy disc forgings formed using the existing die-forging process, and their microstructure was observed. The microstructure of the hub area is shown in the image below. Figure 9 As shown, the grain structure is coarse equiaxed crystals with an average grain size of 76.8 μm; the microstructure of the rim region is shown in the figure below. Figure 10 As shown, the grain structure consists of deformed coarse grains and very few fine grains, with an average grain size of 70.1 μm.

[0130] High-temperature alloy disc forgings formed using existing die forging processes exhibit deformation dead zones in the hub region and cold-formed microstructures with coarse grains in the rim region. Compared to the microstructure of the hub and rim regions in the specific embodiment, the microstructure uniformity is poor. In other words, this invention allows for the control of the microstructure uniformity of high-temperature alloy disc forgings.

[0131] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications, equivalent substitutions, and improvements made by those skilled in the art within the scope of the technology disclosed in the present invention, and within the spirit and principles of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for partial additive manufacturing and zoned die forging of high-temperature alloy disc-shaped forgings, characterized in that, Includes the following steps: S1: Based on the structural complexity of different areas of high-temperature alloy disc forgings, precast billets are divided into base billets and additive billets; S2: Locally additively manufacture additive billets on a base blank to obtain preformed billets; S3: Heat-treat the precast billet to obtain a forged billet; S4: Determine the small deformation zone of the forging blank based on the deformation amount and dynamic recrystallization fraction in different regions of the forging blank; S5: Perform zoned die forging on the forging billet to obtain high-temperature alloy disc-shaped forgings; In S4, the small deformation zone is set as the forging billet area with a deformation amount of 0~40% and / or a dynamic recrystallization fraction of 0~50%. In S5, partitioned die forging includes: heating the forging billet to the forming temperature and holding it at that temperature; Preheat the mold; perform pre-forging of the small deformation zone of the forging billet by placing the pad under the inner lower mold, placing the heated forging billet on the lower mold, and pressing down the upper mold to complete the pre-forging of the small deformation zone of the forging billet; perform overall die forging of the forging billet by removing the pad, adjusting the positions of the outer lower mold and the inner lower mold, and pressing down the upper mold to obtain a high-temperature alloy disc forging.

2. The method for partial additive manufacturing and zoned die forging of high-temperature alloy disc-shaped forgings as described in claim 1, characterized in that: In S1, the base blank is a forging region with low structural complexity that can be formed in one blanking process, while the additive blank is a forging region with high structural complexity that is difficult to form in one blanking process.

3. The method for partial additive manufacturing and zoned die forging of high-temperature alloy disc-shaped forgings as described in claim 1, characterized in that: In step S2, the surface of the substrate blank is polished and cleaned; the additive material is the same as that of the substrate blank; the additive current is 50~300A, the additive voltage is 5~40V, the wire feeding speed is 0.1~20m / min, the additive speed is 0.1~10m / min, the protective gas is an atmosphere of argon mixed with 0~40% carbon dioxide, the gas flow rate is 5~30L / min, and the interlayer cooling is 0~30min.

4. The method for partial additive manufacturing and zoned die forging of high-temperature alloy disc-shaped forgings as described in claim 1, characterized in that: In step S3, the heat treatment includes: homogenizing the preform at a temperature of 900~1200℃ for 0.1~5h and cooling it with water; and aging the homogenized preform at a temperature of 800~1000℃ for 0.5~48h and cooling it with air.

5. A system for partial additive manufacturing and partitioned die forging of high-temperature alloy disc forgings, implementing the partial additive manufacturing and partitioned die forging method for high-temperature alloy disc forgings as described in any one of claims 1-4, characterized in that, The system includes: The billet division module divides precast billets into base billets and additive billets based on the structural complexity of different areas of high-temperature alloy disc forgings. The precast billet manufacturing module is connected to the billet dividing module. It locally additively manufactures additive billets on the base blank to obtain precast billets. The heat treatment module is connected to the precast billet manufacturing module to perform heat treatment on the precast billet to obtain a forging billet; The small deformation zone determination module is connected to the heat treatment module. It determines the small deformation zone of the forging billet based on the deformation amount and dynamic recrystallization fraction of different regions of the forging billet. The partitioned die forging module is connected to the small deformation zone determination module to perform partitioned die forging on the forging billet to obtain high-temperature alloy disc-shaped forgings.

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