GH4093 high-temperature alloy forge piece and manufacturing method thereof

Abstract

The invention relates to a GH4093 high-temperature alloy forge piece and a manufacturing method thereof, and belongs to the technical field of metal processing. The manufacturing method comprises the following steps that vacuum induction smelting is conducted, a Ni-B alloy optimization refining process is adopted, and the purity and the component uniformity of molten steel are improved; vacuum consumable smelting is carried out, metal is further purified, the crystal structure is improved, and segregation is reduced; forging and cogging, and preparing a high-quality blank through upsetting, drawing and repeated remelting and heating; forging into a material, and forging a large-small-head structure forging blank by adopting an optimized process; and heat treatment is conducted, and through solid solution and aging treatment, the grain structure and the mechanical property are remarkably improved. The obtained forge piece comprises the following chemical components: 0.05%-0.08% of C, 18.0%-21.0% of Cr, 15.0%-21.0% of Co, 1.0%-2.0% of Al, 2.0%-3.0% of Ti, less than or equal to 0.02% of B and the balance of Ni and impurities. The manufacturing method is advanced in process and stable in product quality, the comprehensive performance and size precision of the manufactured forged piece are remarkably improved, and the requirements of aviation, nuclear energy and other high-end fields for high-temperature alloy forged pieces of complex structures are met.

Description

Technical Field

[0001] The present invention relates to the technical field of metal processing, and in particular to a GH4093 high temperature alloy forging and a manufacturing method thereof. Background Art

[0002] GH4093 is a precipitation-strengthened nickel-based high-temperature alloy widely used in turbine disks, turbine blades and other high-temperature components in the aerospace field. This material can maintain good strength and stability at high temperatures of 600°C to 800°C due to its excellent high-temperature creep resistance, oxidation resistance and fatigue resistance. However, in the existing technology, the manufacturing process of GH4093 alloy forgings still faces the following technical difficulties and defects:

[0003] It is difficult to control the uniformity of composition: The composition of GH4093 alloy contains a variety of high melting point elements (such as Cr, Co, Mo and W). During the smelting and forging process, these elements are prone to segregation, resulting in uneven distribution of composition. This segregation will directly affect the mechanical properties and high temperature stability of the alloy, especially in large-sized forgings. In the existing technology, it is difficult to completely eliminate this segregation by traditional smelting and heat treatment methods.

[0004] Effect of forging process parameters on grain size control: Grain size is a key factor affecting the comprehensive performance of high-temperature alloy forgings. Small and uniform grains can significantly improve the high-temperature strength, creep performance and ductility of the material. However, in the existing forging process, improper control of temperature and deformation rate may lead to grain growth or uneven deformation, which in turn affects the high-temperature performance of the material.

[0005] The contradiction between mechanical properties and grain size: In the existing process, in order to pursue high strength, it is usually necessary to refine the grains. However, excessive refinement may lead to reduced plasticity and toughness of the material, thereby limiting the service life of the forging under complex stress conditions. Therefore, how to achieve the best balance between strength and plasticity is a major technical difficulty in the production of GH4093 forgings.

[0006] Insufficient heat treatment process: During the solution treatment and aging treatment of GH4093 alloy forgings, the temperature and holding time need to be precisely controlled to ensure the sufficient precipitation and uniform distribution of strengthening phases (such as γ' phase). However, the existing heat treatment process often fails to take into account the grain refinement, internal stress elimination and optimization of precipitation phase distribution, resulting in large fluctuations in the mechanical properties of forgings.

[0007] The contradiction between dimensional accuracy and defect control: In the existing technology, large-scale manufacturing of GH4093 forgings is prone to dimensional deviation and surface defects such as cracks and scale. These defects not only affect subsequent processing, but also significantly reduce the reliability of forgings.

[0008] In summary, the existing technology has problems such as poor composition uniformity, insufficient grain size control, unstable mechanical properties, and difficulty in controlling size and surface quality in the manufacturing process of GH4093 alloy forgings, which seriously limits the further application of this material in high-end fields such as aerospace. Therefore, it is urgent to develop an optimized manufacturing method to achieve high performance and high reliability of GH4093 alloy forgings and provide a better solution for complex high-temperature working conditions. Summary of the invention

[0009] The technical problem to be solved by the present invention is to provide a method for manufacturing GH4093 high temperature alloy forgings to solve the problems of uneven grain structure, unstable mechanical properties and difficult forming of complex structure forgings in conventional manufacturing methods in the prior art.

[0010] In order to overcome the above defects of the prior art, the present invention provides a method for manufacturing a GH4093 high temperature alloy forging, which is characterized by comprising the following steps: S1: vacuum induction smelting electrode rod; Metal Cr, metal Co and electrolytic Ni are loaded as raw materials into a vacuum induction furnace, and the vacuum is drawn and electricity is supplied to melt the raw materials; then metal Al and metal Ti are added for refining, and after the refining is completed, samples are taken to analyze the chemical composition, and when the chemical composition is qualified, Ni-B alloy is added, and the steel is produced after further refining; the molten steel is poured into an ingot mold, and cooled to room temperature to obtain an electrode rod; S2: Vacuum self-consumable production of steel ingots; The electrode rod is polished until the surface is metallic and then loaded into a vacuum consumable furnace, evacuated and electrically melted to complete the vacuum consumable remelting process to obtain a steel ingot with high purity and low segregation; S3: Forging and blanking; After the surface of the steel ingot is polished, it is loaded into a heating furnace, heated and kept warm before being taken out of the furnace; the steel ingot is first upset on a forging device, and then drawn to form a square billet; after returning to the furnace and keeping warm for 1 hour, it is taken out of the furnace again and forged into a round bar, and air-cooled to room temperature after forging; S4: Forged materials; Cutting the round bar blank; loading the blank into a heating furnace, heating and keeping the blank warm before taking it out of the furnace, and forging it into a square billet on a forging device; returning the blank to the furnace for keeping the blank warm before taking it out of the furnace, first drawing it into a square billet, and then further forging it into a forging blank with a large and small head structure, wherein the cross-sectional size of the large head at one end and the cross-sectional size of the small head at the other end are connected through a transition area, and the blank is air-cooled to room temperature after forging; S5: heat treatment; Solution treatment: adding the forging blank into a heating furnace for solution treatment; Aging treatment: The forging blank after solution treatment is loaded into the heating furnace again for aging treatment.

[0011] Compared with the prior art, the manufacturing method of a GH4093 high temperature alloy forging provided in the present application has the following advantages: Precise control of composition and structural uniformity: The manufacturing method of the present invention significantly improves the purity and composition uniformity of molten steel through vacuum induction melting combined with Ni-B alloy optimization process; vacuum self-consumption further reduces segregation problems; Precise forming of high-performance forgings: Optimizing the forging process, using multiple reheating, upsetting and drawing steps to successfully solve the problem of forming forgings with complex shapes, ensuring the high quality and dimensional accuracy of large and small head forgings; Significantly improve mechanical properties: The manufacturing method of the present invention obtains uniform grain structure through precise solid solution and aging heat treatment. The mechanical property test results (such as room temperature tensile and high temperature endurance performance) show that the forgings fully meet the technical standard requirements and have stable and reliable performance; The manufacturing method of the present invention adopts a high vacuum environment and step-by-step temperature-controlled heat treatment, so that the strengthening elements (such as Al and Ti) in the alloy are evenly distributed and fully dissolved, effectively improving the high-temperature performance and service stability of the forgings, while ensuring the processing adaptability and surface quality of complex structures; through innovative process design and precise parameter control, not only the segregation problem in the prior art is solved, but also the efficient manufacturing of high-strength, high-plasticity, complex-structure GH4093 high-temperature alloy forgings is achieved, providing reliable guarantee for applications in high-end fields such as aviation and nuclear power.

[0012] In a possible implementation manner, after step S5, step S6 of sampling inspection, machining and flaw detection is further included, including: S6: Sampling inspection, machining and flaw detection: After the big head of the forging is cut off, samples are taken to test the chemical composition, room temperature tensile properties, and high temperature endurance properties to ensure that the forging performance meets the technical standards. Subsequently, the qualified forgings are polished and the excess parts are cut off according to the size requirements. The forgings are ultrasonically tested using the GB / T4162 standard to obtain finished forgings.

[0013] Compared with the existing technology, the above technical solution can representatively test the internal structure uniformity and mechanical properties of the forging by cutting off the big head of the forging and taking samples at key positions (such as 1 / 2 radius of the cross section), ensuring that the quality of the final product meets strict technical standards; the oxide layer and defects in the processing process are eliminated by surface polishing, and then combined with ultrasonic flaw detection to detect hidden defects, it can effectively eliminate potential problems such as internal cracks and inclusions, thereby improving the service safety and reliability of the forging; the above implementation method significantly improves the overall performance stability and reliability of the forging through standardized sampling, physical and chemical testing and flaw detection processes, providing strong quality assurance for high-temperature service in downstream applications.

[0014] In a possible implementation, in step S1, the conditions for evacuating the vacuum and sending the electric melting are: evacuating the vacuum to ≤1.0 Pa, and sending the electric melting to a temperature of the molten steel of ≥1520°C.

[0015] Compared with the prior art, the above technical solution can effectively remove residual impurity gases such as oxygen and nitrogen in the furnace by vacuuming to ≤1.0 Pa, reduce the influence of dissolved gases on the purity of molten steel, avoid uneven composition caused by oxide inclusions and nitride formation, and ensure that the metal raw materials are fully melted by sending electricity to melt the molten steel until the temperature of the molten steel is ≥1520°C. At the same time, it provides the best reaction temperature range for the subsequent addition of alloy elements (such as Al and Ti), avoiding uneven distribution of alloy elements due to insufficient temperature. Moreover, under high temperature conditions above 1520°C, the metal raw materials are completely melted to form a uniform molten steel, reducing the possibility of local component segregation, laying the foundation for subsequent refining and alloy composition adjustment, and ultimately providing high-quality initial materials for subsequent processes, ensuring that the mechanical properties and service reliability of the forgings fully meet the technical requirements of high-end application fields.

[0016] In a possible implementation, in the step S1, the refining time is greater than or equal to 1 hour, and the continued refining time is 10-15 minutes.

[0017] Compared with the prior art, the above technical solution is adopted to set the refining time to be greater than or equal to 1 hour, which can fully remove the dissolved gases (such as O, N, H) and volatile impurities in the molten steel, and at the same time fully separate the slag from the inclusions in the molten metal, thereby improving the purity of the molten steel; and continuing to refining for 10-15 minutes provides a sufficient time window, so that key alloy elements (such as Al, Ti, Ni-B) can be evenly distributed in the molten steel and completely react with residual impurities (such as oxygen), avoiding composition deviation or impurity residue caused by insufficient reaction. By adding Ni-B alloy after the refining is completed and controlling the refining time to 10-15 minutes, it can be ensured that the B element is evenly dissolved, avoiding volatilization of B or excessive reaction due to too long a time, thereby optimizing the strengthening phase distribution and grain structure of the alloy.

[0018] In a possible implementation, in step S2, the vacuuming condition is that the vacuum degree in the furnace is ≤0.1Pa.

[0019] Compared with the existing technology, the above technical solution effectively balances the needs of impurity volatilization and alloy element protection through a high vacuum environment of ≤0.1Pa, reducing the problem of impurity residue or element loss in traditional processes. This technical solution ensures the purity and composition uniformity of the steel ingot while providing a reliable foundation for the high performance of the forgings. It is particularly suitable for high-performance alloy materials serving under extreme high temperature conditions, further improving the advancement of the manufacturing process and the competitiveness of the materials.

[0020] In a possible implementation, in step S3, the charging temperature of the blank is ≤600°C, and the heating and heat preservation conditions are: heating to 1100±10°C for 5 hours, and heat preservation for 5 hours.

[0021] Compared with the prior art, the above technical scheme can significantly reduce the amount of oxide scale generated on the surface of the billet during the heating process by controlling the charging temperature of the billet to ≤600°C, lowering the charging temperature and controlling the heating rate, further reducing the impact of oxide scale cleaning on production efficiency, and effectively avoiding the thermal shock phenomenon caused by the large temperature difference between the billet and the furnace, thereby reducing the generation of cracks on the billet surface and internal thermal stress. The slow heating process of heating to 1100±10°C for 5 hours gradually reduces the temperature difference between the inside and outside of the billet, ensuring that the entire billet is heated in a uniform state, providing stable material conditions for subsequent forging, and under the insulation condition of 1100±10°C, the recrystallization process of the billet can be fully carried out, the grains are refined and evenly distributed, which helps to improve the plasticity and toughness of the metal.

[0022] In a possible implementation, in step S4, the charging temperature of the blank is ≤600°C, and the heating and heat preservation conditions are: heating to 1100±10°C, heat preservation for 4 hours, and the return to the furnace and heat preservation time is 1 hour.

[0023] Compared with the prior art, the above technical solution is adopted to control the charging temperature of the billet to ≤600℃, which can effectively reduce the temperature difference between the billet and the furnace, avoid cracks and internal stress concentration caused by thermal shock, ensure the structural integrity of the billet during the heating process, heat to 1100±10℃ and keep warm for 4 hours to ensure that the billet as a whole reaches the optimal temperature required for forging, which is helpful to improve the plasticity of the metal and reduce the local stress caused by the internal temperature difference. Under the condition of returning to the furnace and keeping warm for 1 hour, the internal stress and temperature gradient after the initial forging are eliminated, so that the billet has a better organizational state during further forging, and the formation of cracks or other defects during the reprocessing process is reduced. By strictly controlling the holding time, the problem of grain coarsening caused by too long a time is avoided. At the same time, it is ensured that the grains are homogenized during the heating and holding process, thereby enhancing the comprehensive mechanical properties of the material.

[0024] In a possible embodiment, in step S5, the conditions of the solution treatment are: heating the blank to 1060±10°C and keeping it for 8 hours, then taking it out of the furnace and air cooling it to room temperature; the conditions of the aging treatment are: heating the blank to 710±10°C and keeping it for 12 hours, then taking it out of the furnace and air cooling it to room temperature.

[0025] Compared with the prior art, the above technical scheme is adopted to heat the blank to 1060±10°C during the solution treatment process to reach the dissolution temperature of the alloy strengthening phase, so that the main strengthening elements (such as Ti and Al) in the alloy are uniformly dissolved in the matrix, eliminating segregation and structural unevenness, and providing a uniform structural basis for subsequent aging treatment; the aging treatment heats the blank to 710±10°C and keeps it warm for 12 hours, providing sufficient time for the strengthening phase (including Ni3(Ti,Al)) to be uniformly precipitated and refined in the matrix. This precipitation strengthening mechanism significantly improves the high-temperature strength and creep resistance of forgings; air cooling after solution treatment effectively avoids stress concentration and crack risks caused by rapid cooling, while refining the grains; through the combination of solution and aging treatment, the heat treatment process of forgings is precisely controlled, taking into account the comprehensive optimization of strength, toughness and fatigue resistance, which is particularly suitable for the manufacture of key structural parts with high temperature and high strength requirements: aging treatment further stabilizes the crystal structure, reduces internal stress and enhances the dimensional stability of forgings. The optimized design of double heat treatment eliminates micro-defects that may remain in the solution process, and improves the high temperature resistance and fatigue resistance of forgings through aging treatment, especially in a high temperature environment of 800°C, showing excellent mechanical properties and lasting strength.

[0026] The technical problem to be solved by the present invention is to provide a method for manufacturing GH4093 high temperature alloy forgings, so as to solve the problem of unstable mechanical properties of forgings prepared by conventional manufacturing methods in the prior art.

[0027] In order to overcome the defects of the above-mentioned prior art, the present invention provides a GH4093 high-temperature alloy forging, wherein the chemical composition of the forging is: C: 0.05%-0.08%, Si: ≤0.1%, Mn: ≤0.1%, P: ≤0.015%, S: ≤0.005%, Cr: 18.0%-21.0%, Co: 15.0%-21.0%, Al: 1.0%-2.0%, Ti: 2.0%-3.0%, B: ≤0.02%, Fe: ≤1.0%, and the balance is Ni and other inevitable impurities.

[0028] Compared with the prior art, the GH4093 high-temperature alloy forging of the present application has the following advantages: the GH4093 high-temperature alloy forging of the present invention optimizes the vacuum induction smelting and vacuum consumable remelting process, combined with the precise addition of Ni-B alloy and efficient refining measures, effectively reduces the impurity content (such as S, P) in the molten steel, and stabilizes the ratio of key elements (such as Al, Ti, B), significantly improving the room temperature tensile properties and high-temperature durability of the forging, and in the manufacturing method, a forging process combining step-by-step heating, upsetting and drawing is adopted to first form a uniform square billet, and then further forge it into a billet with a large and small head structure, effectively overcoming the problems of cracks and uneven structure caused by the narrow forging temperature range of the high-temperature alloy, and finally achieving a comprehensive improvement in the mechanical properties and dimensional accuracy of the forging, and through the solution + aging heat treatment process, by precisely controlling the temperature (1060°C and 710°C) and the holding time (8 hours and 12 hours, respectively) When the temperature is high (100 °C), uniform precipitation of the strengthening phase and refinement of the matrix grains are achieved, and the high-temperature creep resistance and ductility of the forgings are greatly improved. Through reasonable component ratio (including the optimized ratio of C and Co), combined with high-purity molten steel and precise forging process, the GH4093 forgings prepared by the present invention are significantly superior to the prior art in terms of room temperature tensile properties, high-temperature endurance performance and fatigue resistance, meeting the stringent requirements of high-end fields such as aviation and nuclear power for high-temperature materials. By strictly controlling each step of the process conditions from vacuum smelting to forging, the segregation and internal stress of the forgings are significantly reduced. At the same time, the flaw detection process is optimized to ensure that the flaw detection pass rate of the finished forgings reaches the A-level standard, further improving the consistency and reliability of the product, and effectively solving the problems of uneven component distribution, grain coarsening and unstable performance in the prior art, providing a reliable process guarantee and technical route for the production of high-performance GH4093 high-temperature alloy forgings.

[0029] In a possible embodiment, the chemical composition of the forging is: C: 0.062%, Si: 0.06%, Mn: 0.052%, S: 0.0021%, P: 0.004%, Cr: 19.73%, Co: 17.32%, Al: 1.57%, Ti: 2.75%, B: 0.007%, Fe: 0.36%, and the remainder is Ni and other inevitable impurities.

[0030] Compared with the prior art, the above technical solution further optimizes the chemical composition of the forgings to ensure the optimal carbon content at 0.062%, strengthens the matrix structure, and avoids the brittleness problem caused by excessive carbon. The optimization of silicon and manganese content improves the deoxidation effect of molten steel and the grain refinement effect, further improves the high-temperature strength and toughness of the forgings, and strictly controls the sulfur and phosphorus contents to 0.0021% and 0.004%, respectively, significantly reduces grain boundary segregation and crack sensitivity, improves the corrosion resistance and high-temperature service stability of the forgings, and the Cr and Co contents are maintained at 19.73% and 17.32%, ensuring excellent oxidation resistance and high-temperature strength; at the same time, the titanium content is 2.75%, which optimizes the precipitation effect of the strengthening phase and greatly improves the creep resistance of the forgings. The optimization of the aluminum and boron content (1.57% and 0.007%) balances the matrix strengthening and crack resistance, and significantly improves the comprehensive mechanical properties of the forgings. Through the above-mentioned composition optimization, the service reliability of the prepared GH4093 high-temperature alloy forgings in high-temperature environments is significantly improved, which can meet the requirements of high-end fields such as aviation and nuclear power for consistency and long-term stability of material properties. DETAILED DESCRIPTION

[0031] First, those skilled in the art should understand that these implementations are only used to explain the technical principles of the embodiments of the present application, and are not intended to limit the protection scope of the embodiments of the present application. Those skilled in the art can make adjustments to them as needed to adapt to specific application scenarios.

[0032] The present invention provides a method for manufacturing a GH4093 high temperature alloy forging, comprising the following steps: S1: vacuum induction smelting electrode rod; Metal Cr, metal Co and electrolytic Ni are loaded as raw materials into a vacuum induction furnace, and the vacuum is drawn and electricity is supplied to melt the raw materials; then metal Al and metal Ti are added for refining, and after the refining is completed, samples are taken to analyze the chemical composition, and when the chemical composition is qualified, Ni-B alloy is added, and the steel is produced after further refining; the molten steel is poured into an ingot mold, and cooled to room temperature to obtain an electrode rod; S2: Vacuum self-consumable production of steel ingots; The electrode rod is polished until the surface is metallic and then loaded into a vacuum consumable furnace, evacuated and electrically melted to complete the vacuum consumable remelting process to obtain a steel ingot with high purity and low segregation; S3: Forging and blanking; After the surface of the steel ingot is polished, it is loaded into a heating furnace, heated and kept warm before being taken out of the furnace; the steel ingot is first upset on a forging device, and then drawn to form a square billet; after returning to the furnace and keeping warm for 1 hour, it is taken out of the furnace again and forged into a round bar, and air-cooled to room temperature after forging; S4: Forged materials; Cutting the round bar blank; loading the blank into a heating furnace, heating and keeping the blank warm before taking it out of the furnace, and forging it into a square billet on a forging device; returning the blank to the furnace for keeping the blank warm before taking it out of the furnace, first drawing it into a square billet, and then further forging it into a forging blank with a large and small head structure, wherein the cross-sectional size of the large head at one end and the cross-sectional size of the small head at the other end are connected through a transition area, and the blank is air-cooled to room temperature after forging; S5: heat treatment; Solution treatment: adding the forging blank into a heating furnace for solution treatment; Aging treatment: The forging blank after solution treatment is loaded into the heating furnace again for aging treatment.

[0033] As a preferred solution, after step S5, step S6 of sampling inspection, machining and flaw detection is also included, including: S6: Sampling inspection, machining and flaw detection: After the big head of the forging is cut off, samples are taken to test the chemical composition, room temperature tensile properties, and high temperature endurance properties to ensure that the forging performance meets the technical standards. Subsequently, the qualified forgings are polished and the excess parts are cut off according to the size requirements. The forgings are ultrasonically tested using the GB / T4162 standard to obtain finished forgings.

[0034] The manufacturing method of the present invention adopts a 1600-ton fast forging machine to produce GH4093 large and small head forgings, which overcomes the problem of the narrow forging temperature range of the alloy. GH4093 high-temperature alloy large and small head forgings with qualified mechanical properties are forged in two fires, wherein the large and small heads are forged in one fire of forging the material, and the process design and forging operation are innovative.

[0035] As a preferred solution, in step S1, the conditions for evacuating the vacuum and sending the electric melting are: evacuating the vacuum to ≤1.0 Pa, and sending the electric melting to the temperature of the molten steel ≥1520°C.

[0036] As a preferred solution, in step S1, the refining time is greater than or equal to 1 hour, and the continued refining time is 10-15 minutes.

[0037] As a preferred solution, in step S2, the vacuuming condition is that the vacuum degree in the furnace is ≤0.1Pa.

[0038] As a preferred solution, in step S3, the charging temperature of the blank is ≤600°C, and the heating and heat preservation conditions are: heating to 1100±10°C for 5 hours and heat preservation for 5 hours.

[0039] As a preferred solution, in step S4, the charging temperature of the blank is ≤600°C, and the heating and heat preservation conditions are: heating to 1100±10°C, heat preservation for 4 hours, and the return to the furnace and heat preservation time is 1 hour.

[0040] As a preferred scheme, in step S5, the conditions of the solution treatment are: heating the blank to 1060±10℃, keeping it warm for 8 hours, then taking it out of the furnace and air cooling it to room temperature; the conditions of the aging treatment are: heating the blank to 710±10℃, keeping it warm for 12 hours, then taking it out of the furnace and air cooling it to room temperature.

[0041] The present invention also provides a GH4093 high-temperature alloy forging, wherein the chemical composition of the forging is: C: 0.05%-0.08%, Si: ≤0.1%, Mn: ≤0.1%, P: ≤0.015%, S: ≤0.005%, Cr: 18.0%-21.0%, Co: 15.0%-21.0%, Al: 1.0%-2.0%, Ti: 2.0%-3.0%, B: ≤0.02%, Fe: ≤1.0%, and the balance is Ni and other inevitable impurities.

[0042] As a preferred solution, the chemical composition of the forging is: C: 0.062%, Si: 0.06%, Mn: 0.052%, S: 0.0021%, P: 0.004%, Cr: 19.73%, Co: 17.32%, Al: 1.57%, Ti: 2.75%, B: 0.007%, Fe: 0.36%, and the remainder is Ni and other inevitable impurities.

[0043] The following is a further explanation and description of the above-mentioned technical solutions of the present invention in combination with specific data: Example 1 This embodiment provides a GH4093 high temperature alloy forging and a manufacturing method thereof. The chemical composition of the GH4093 high temperature alloy forging is: C: 0.062%, Si: 0.06%, Mn: 0.052%, S: 0.0021%, P: 0.004%, Cr: 19.73%, Co: 17.32%, Al: 1.57%, Ti: 2.75%, B: 0.007%, Fe: 0.36%, and the balance is Ni and other inevitable impurities.

[0044] The manufacturing method steps are as follows: S1: Vacuum induction smelting electrode rod Metal Cr, metal Co, and electrolytic Ni are loaded into a vacuum induction furnace as raw materials. After the vacuum is evacuated to ≤1.0Pa, they are sent for electric melting. When the metal is completely melted and the temperature reaches 1520℃, metal Al and metal Ti are added for refining for 1 hour. After the refining is completed, samples are taken to analyze the chemical composition. When the chemical composition is qualified, Ni-B alloy is added, and the steel is tapped after refining for 10 minutes. The molten steel is poured into a Φ440mm ingot mold, cooled for 2 hours, demolded, and air-cooled to room temperature to obtain an electrode rod.

[0045] S2: Vacuum self-consumption production of steel ingots The electrode rod is polished to a metallic luster and then loaded into a vacuum consumable furnace. After the vacuum is evacuated to ≤0.1 Pa, it is sent for electric melting to complete the vacuum consumable remelting process to obtain a Φ508mm steel ingot with high purity and low segregation.

[0046] S3: Forging The steel ingot is polished to the actual size of Φ485mm and then loaded into a natural gas heating furnace, heated to 1100℃ for 5 hours, and then taken out of the furnace after being kept warm for 5 hours. A 5000-ton fast forging machine is used to first upset the steel ingot to half of its original height, then elongate it to form a 500mm×500mm square billet, return it to the furnace and keep warm for 1 hour before forging it again into a Φ420mm round bar. After forging, it is air-cooled to room temperature to complete the forging and blanking step.

[0047] S4: Forged materials The Φ420mm round bar blank is cut at 970kg / piece, and the blank size is Φ420mm×855mm. The blank is reloaded into the electric heating furnace, heated to 1100℃ for 5 hours, and taken out of the furnace after keeping warm for 4 hours, and forged into 300mm×300mm×1315mm square billet on a 1600-ton fast forging machine; it is returned to the furnace and kept warm for 1 hour and then taken out of the furnace again, first drawn to 235mm×235mm square billet, then chamfered at 385mm from the end, forged into Φ135mm×1482mm, and then turned around and forged into Φ235mm×2150mm forging blank, with the final size of Φ235mm×2150mm+Φ135mm×1482mm. After forging, it is air-cooled to room temperature.

[0048] S5: Heat treatment Solution treatment: the forging blank is placed in an electric heating furnace, heated to 1060° C. and kept at this temperature for 8 hours, and then taken out of the furnace and air-cooled to room temperature.

[0049] Aging treatment: The forging blank after solution treatment is reloaded into the electric heating furnace, heated to 710℃ and kept at this temperature for 12 hours, then taken out of the furnace and air-cooled to room temperature.

[0050] S6: Sampling inspection and machining flaw detection After cutting off 100mm of the forging head, a 60mm long sample is cut to test the chemical composition, room temperature tensile properties and high temperature endurance properties. After the performance test is qualified, the forging surface is polished and sized: After the forging physical and chemical inspection is qualified, the surface is polished and the forging is cut according to the Figure 1 The size requires that the excess part be cut off to obtain the finished forging size of Φ225*1950+Φ135*1182mm, with a total length of 3132mm. Figure 1 As shown, Figure 1The forging dimensions and schematic diagram of the forging are finally obtained in Example 1.

[0051] Ultrasonic flaw detection is performed on forgings in accordance with GB / T4162 standard to ensure that the flaw detection reaches Class A standard and finally obtain finished forgings.

[0052] The mechanical properties of the forgings obtained in Example 1 above were tested, and the test results are shown in the following table: Table 1: Example 2 This embodiment provides a GH4093 high temperature alloy forging and a manufacturing method thereof. The chemical composition of the GH4093 high temperature alloy forging is: C: 0.05%, Si: 0.1%, Mn: 0.1%, S: 0.005%, P: 0.015%, Cr: 18.0%, Co: 15.0%, Al: 1.0%, Ti: 2.0%, B: 0.02%, Fe: 1.0%, and the balance is Ni and other inevitable impurities.

[0053] The manufacturing method comprises: S1: Vacuum induction smelting electrode rod Metal Cr, metal Co, and electrolytic Ni are loaded into a vacuum induction furnace as raw materials, and the vacuum is evacuated to ≤1.0Pa. Electric melting is performed until the metal is completely melted and the temperature reaches 1530℃. Then metal Al and metal Ti are added for refining for 1 hour. After refining, samples are taken to analyze the chemical composition. When the chemical composition is qualified, Ni-B alloy is added, and the steel is tapped after further refining for 15 minutes. The molten steel is poured into a Φ440mm ingot mold, cooled for 2 hours, and then demolded and air-cooled to room temperature to obtain an electrode rod.

[0054] S2: Vacuum self-consumption production of steel ingots The electrode rod is polished to a metallic luster and then loaded into a vacuum consumable furnace, evacuated to ≤0.1 Pa, and powered for melting to complete the vacuum consumable remelting process to obtain a Φ508 mm steel ingot with high purity and low segregation.

[0055] S3: Forging The steel ingot is polished to the actual size of Φ485mm and then loaded into a natural gas heating furnace, heated to 1090℃ for 5 hours, and then taken out of the furnace after being kept warm for 5 hours. A 5000-ton fast forging machine is used to first upset the steel ingot to half of its original height, then elongate it to form a 500mm×500mm square billet, return it to the furnace and keep warm for 1 hour before forging it again into a Φ420mm round bar. After forging, it is air-cooled to room temperature to complete the forging and blanking step.

[0056] S4: Forged materials The Φ420mm round bar blank is cut at 970kg / piece, and the blank size is Φ420mm×855mm. The blank is reloaded into the electric heating furnace, heated to 1090℃ for 5 hours, and taken out of the furnace after keeping warm for 4 hours, and forged into 300mm×300mm×1315mm square billet on a 1600-ton fast forging machine; returned to the furnace and kept warm for 1 hour before being taken out of the furnace again, first drawn to 235mm×235mm square billet, then chamfered at 385mm from the end, forged into Φ135mm×1482mm, and then turned around and forged into Φ235mm×2150mm forging blank, with the final size of Φ235mm×2150mm+Φ135mm×1482mm. After forging, air cool to room temperature.

[0057] S5: Heat treatment Solution treatment: The forging blank is placed in an electric heating furnace, heated to 1055° C. and kept at this temperature for 8 hours, and then taken out of the furnace and air-cooled to room temperature.

[0058] Aging treatment: The forging blank after solution treatment is reloaded into the electric heating furnace, heated to 705℃ and kept at this temperature for 12 hours, then taken out of the furnace and air-cooled to room temperature.

[0059] S6: Sampling inspection and machining flaw detection After cutting off 100mm of the forging head, a 60mm long sample is cut to test the chemical composition, room temperature tensile properties and high temperature endurance properties. After the performance test is qualified, the forging surface is polished and the excess part is cut off according to the finished product size requirements. According to GB / T4162 standard, ultrasonic flaw detection is carried out on the forging to ensure that the flaw detection reaches the A-level standard, and finally the finished forging is obtained.

[0060] Example 3 This embodiment provides a GH4093 high temperature alloy forging and a manufacturing method thereof. The chemical composition of the GH4093 high temperature alloy forging is: C: 0.08%, Si: 0.08%, Mn: 0.09%, S: 0.004%, P: 0.014%, Cr: 21.0%, Co: 20.0%, Al: 2.0%, Ti: 3.0%, B: 0.015%, Fe: 0.8%, and the balance is Ni and other inevitable impurities.

[0061] The manufacturing method comprises: S1: Vacuum induction smelting electrode rod Metal Cr, metal Co, and electrolytic Ni are loaded into a vacuum induction furnace as raw materials, and the vacuum is evacuated to ≤1.0Pa. Electric melting is performed until the metal is completely melted and the temperature reaches 1525℃. Then metal Al and metal Ti are added for refining for 1 hour. After refining, samples are taken to analyze the chemical composition. When the chemical composition is qualified, Ni-B alloy is added, and the steel is tapped after further refining for 12 minutes. The molten steel is poured into a Φ440mm ingot mold, cooled for 2 hours, and then demolded and air-cooled to room temperature to obtain an electrode rod.

[0062] S2: Vacuum self-consumption production of steel ingots The electrode rod is polished to a metallic luster and then loaded into a vacuum consumable furnace, evacuated to ≤0.1 Pa, and powered for melting to complete the vacuum consumable remelting process to obtain a Φ508 mm steel ingot with high purity and low segregation.

[0063] S3: Forging The steel ingot is polished to the actual size of Φ485mm and then loaded into a natural gas heating furnace, heated to 1110℃ for 5 hours, and then taken out of the furnace after being kept warm for 5 hours. A 5000-ton fast forging machine is used to first upset the steel ingot to half of its original height, then elongate it to form a 500mm×500mm square billet, return it to the furnace and keep warm for 1 hour before forging it again into a Φ420mm round bar. After forging, it is air-cooled to room temperature to complete the forging and blanking step.

[0064] S4: Forged materials The Φ420mm round bar blank is cut at 970kg / piece, and the blank size is Φ420mm×855mm. The blank is reloaded into the electric heating furnace, heated to 1110℃ for 5 hours, and taken out of the furnace after keeping warm for 4 hours, and forged into 300mm×300mm×1315mm square billet on a 1600-ton fast forging machine; it is returned to the furnace and kept warm for 1 hour and then taken out of the furnace again, first drawn to 235mm×235mm square billet, then chamfered at 385mm from the end, forged into Φ135mm×1482mm, and then turned around and forged into Φ235mm×2150mm forging blank, with the final size of Φ235mm×2150mm+Φ135mm×1482mm. After forging, it is air-cooled to room temperature.

[0065] S5: Heat treatment Solution treatment: The forging blank is placed in an electric heating furnace, heated to 1070° C. and kept at this temperature for 8 hours, and then taken out of the furnace and air-cooled to room temperature.

[0066] Aging treatment: The forging blank after solution treatment is reloaded into the electric heating furnace, heated to 720℃ and kept warm for 12 hours, then taken out of the furnace and air-cooled to room temperature.

[0067] S6: Sampling inspection and machining flaw detection After cutting off 100mm of the forging head, a 60mm long sample is cut to test the chemical composition, room temperature tensile properties and high temperature endurance properties. After the performance test is qualified, the forging surface is polished and the excess part is cut off according to the finished product size requirements. According to GB / T4162 standard, ultrasonic flaw detection is carried out on the forging to ensure that the flaw detection reaches the A-level standard, and finally the finished forging is obtained.

[0068] The above embodiments further prove that the present invention provides a GH4093 high temperature alloy forging and a manufacturing method thereof. The method solves several key problems existing in the background technology through the following technical principles:

[0069] Composition uniformity control: The present invention adopts vacuum induction smelting combined with Ni-B alloy optimization refining process, which significantly reduces the content of impurities (such as S, P) in molten steel, inhibits the occurrence of segregation, and ensures the precise proportion and uniform distribution of key elements (such as Cr, Co, Ti, Al). At the same time, the metal is further purified through vacuum consumable smelting, the crystal structure of the steel ingot is improved, and the problem of mechanical property fluctuation caused by uneven composition in conventional processes is avoided.

[0070] Forging process optimization: The manufacturing method of the present invention ensures the grain uniformity of the forging blank by accurately controlling the forging temperature and the process steps of multiple heating, upsetting and drawing, and avoids the cracking and grain coarsening problems caused by the narrow temperature range in the traditional process. In particular, the combination of multiple reheating and gradual deformation enhances the internal consistency of the material and the dimensional accuracy of the final product.

[0071] Strengthening phase precipitation control: The manufacturing method of the present invention combines solution treatment with aging treatment, and through precise temperature and holding time design (solution treatment temperature 1060±10°C, holding time 8 hours; aging treatment temperature 710±10°C, holding time 12 hours), achieves uniform precipitation of strengthening phases (such as Ni3(Ti,Al)) and refinement of matrix grains, thereby significantly improving the high temperature strength and creep resistance of the material.

[0072] Unstable mechanical properties: The manufacturing method of the present invention significantly improves the room temperature tensile properties of the forgings by optimizing the refining process and heat treatment parameters. The measured values ​​show that the yield strength (σ0.2) is 728 MPa, the tensile strength (σb) is 1123 MPa, and the elongation (δ5) is 27%, all of which are higher than the technical standard requirements (≥700 MPa, ≥1100 MPa, ≥20%), indicating that the forgings have excellent strength and plasticity matching at room temperature.

[0073] Insufficient reliability in high temperature service: Regarding the long-lasting performance under high-temperature conditions of 800°C, the forgings prepared by the present invention have a fracture time of 46 hours under a stress of 300 MPa, which is significantly better than the 30 hours required by the standard. At the same time, the elongation under high-temperature conditions reaches 18.5%, further verifying the superior performance and stability of the material under high-temperature and high-stress conditions.

[0074] Grain coarsening and dimensional accuracy: The manufacturing method of the present invention optimizes the solid solution and aging treatment processes, controls grain refinement while maintaining uniform distribution, and eliminates the brittleness problem caused by grain growth. In addition, the coordinated optimization of forging and heat treatment significantly improves the dimensional accuracy of the finished forgings, ensures the shape stability of complex structures (large and small head forgings), and meets the strict requirements for forging quality in high-end fields such as aviation and nuclear power.

[0075] In summary, the present invention not only solves the problems of composition segregation, mechanical property fluctuation and insufficient high-temperature service stability existing in the background technology through comprehensive optimization of composition, organization and mechanical properties, but also achieves significant improvement in the mechanical properties, dimensional accuracy and comprehensive service performance of forgings, providing reliable guarantee for the application of GH4093 high-temperature alloy forgings in high-end fields such as aerospace and nuclear power.

[0076] In the description of the present application, the description with reference to the terms "one embodiment", "some embodiments", "in the present embodiment", "specific example", or "some examples" etc. means that the specific features, mechanisms, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, mechanisms, materials or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0077] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions that can be easily thought of by a person skilled in the art within the technical scope disclosed in the present application should be included in the protection scope of the present application. Therefore, the protection scope of the present application shall be based on the protection scope of the claims.

Claims

1. A method for manufacturing a GH4093 high temperature alloy forging, characterized in that: The following steps are involved: S1: vacuum induction smelting electrode rod; Metal Cr, metal Co and electrolytic Ni are loaded as raw materials into a vacuum induction furnace, and the vacuum is drawn and electricity is supplied to melt the raw materials; then metal Al and metal Ti are added for refining, and after the refining is completed, samples are taken to analyze the chemical composition, and when the chemical composition is qualified, Ni-B alloy is added, and the steel is produced after further refining; the molten steel is poured into an ingot mold, and cooled to room temperature to obtain an electrode rod; S2: Vacuum self-consumable production of steel ingots; The electrode rod is polished until the surface is metallic and then loaded into a vacuum consumable furnace, evacuated and electrically melted to complete the vacuum consumable remelting process to obtain a steel ingot with high purity and low segregation; S3: Forging and blanking; After the surface of the steel ingot is polished, it is loaded into a heating furnace, heated and kept warm before being taken out of the furnace; the steel ingot is first upset on a forging device, and then drawn to form a square billet; after returning to the furnace and keeping warm for 1 hour, it is taken out of the furnace again and forged into a round bar, and air-cooled to room temperature after forging; S4: Forged materials; Cutting the round bar blank; loading the cut blank into a heating furnace, heating and keeping the blank warm, and then taking it out of the furnace, and forging it into a square billet on a forging device; After returning to the furnace for heat preservation, it is taken out of the furnace, first drawn to form a square billet, and then further forged to form a forging blank with a large and small head structure, in which the cross-sectional size of the large head at one end and the cross-sectional size of the small head at the other end are connected through a transition area. After forging, the blank is air-cooled to room temperature; S5: heat treatment; Solution treatment: adding the forging blank into a heating furnace for solution treatment; Aging treatment: The forging blank after solution treatment is loaded into the heating furnace again for aging treatment.

2. The method for manufacturing a GH4093 high temperature alloy forging according to claim 1, characterized in that: After step S5, step S6 of sampling inspection, machining and flaw detection is also included, including: S6: Sampling inspection, machining and flaw detection: After the big head of the forging is cut off, samples are taken to test the chemical composition, room temperature tensile properties, and high temperature endurance properties to ensure that the forging performance meets the technical standards. Subsequently, the qualified forgings are polished and the excess parts are cut off according to the size requirements. The forgings are ultrasonically tested using the GB / T4162 standard to obtain finished forgings.

3. The method for manufacturing a GH4093 high temperature alloy forging according to claim 1, characterized in that: In the step S1, the conditions for evacuating the vacuum and sending the electric melting are: evacuating the vacuum to ≤1.0 Pa, and sending the electric melting to the temperature of the molten steel ≥1520°C.

4. The method for manufacturing a GH4093 high temperature alloy forging according to claim 1, characterized in that: In the step S1, the refining time is greater than or equal to 1 hour, and the refining time is 10-15 minutes.

5. The method for manufacturing a GH4093 high temperature alloy forging according to claim 1, characterized in that: In the step S2, the vacuuming condition is that the vacuum degree in the furnace is ≤0.1Pa.

6. The method for manufacturing a GH4093 high temperature alloy forging according to claim 1, characterized in that: In the step S3, the charging temperature of the blank is ≤600°C, and the heating and heat preservation conditions are: heating to 1100±10°C for 5 hours and heat preservation for 5 hours.

7. The method for manufacturing a GH4093 high temperature alloy forging according to claim 1, characterized in that: In the step S4, the charging temperature of the blank is ≤600°C, the heating and heat preservation conditions are: heating to 1100±10°C, heat preservation for 4 hours, and the time of returning to the furnace and heat preservation is 1 hour.

8. The method for manufacturing a GH4093 high temperature alloy forging according to claim 1, characterized in that: In step S5, the conditions for the solution treatment are: heating the blank to 1060±10°C and keeping it for 8 hours, then taking it out of the furnace and air cooling it to room temperature; the conditions for the aging treatment are: heating the blank to 710±10°C and keeping it for 12 hours, then taking it out of the furnace and air cooling it to room temperature.

9. A GH4093 high temperature alloy forging, characterized in that: The chemical composition of the forging is: C: 0.05%-0.08%, Si: ≤0.1%, Mn: ≤0.1%, P: ≤0.015%, S: ≤0.005%, Cr: 18.0%-21.0%, Co: 15.0%-21.0%, Al: 1.0%-2.0%, Ti: 2.0%-3.0%, B: ≤0.02%, Fe: ≤1.0%, and the balance is Ni and other inevitable impurities.

10. The GH4093 high temperature alloy forging according to claim 9, characterized in that: The chemical composition of the forging is: C: 0.062%, Si: 0.06%, Mn: 0.052%, S: 0.0021%, P: 0.004%, Cr: 19.73%, Co: 17.32%, Al: 1.57%, Ti: 2.75%, B: 0.007%, Fe: 0.36%, and the remainder is Ni and other inevitable impurities.

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