Application of double-channel powder feeding process in preparation of blank of turbine disc of aero-engine

Abstract

The invention discloses application of a double-channel powder feeding process in preparation of an aero-engine turbine disc blank, belongs to the technical field of aero-turbine disc manufacturing, and is characterized in that high-temperature alloy powder is subjected to gradient proportioning deposition through a double-channel system by an electric arc powder feeding additive process, and material gradient distribution is formed in disc center, transition and disc edge areas; meanwhile, dynamic mechanical deformation is applied to a new deposition layer in a high-temperature plastic state by adopting a synchronous micro-forging process, hot isostatic pressing treatment is carried out on a prepared turbine disc blank to eliminate internal defects, high-temperature homogenizing annealing is carried out in a vacuum furnace to improve the structure uniformity, and finally, the required mechanical property is obtained through solution treatment and aging treatment. The gradient accurate control of material components in different areas of the turbine disc is realized, the microstructure of a deposition material can be effectively improved, regulated and controlled in the manufacturing process, and metallurgical defects are reduced.

Description

Technical Field

[0001] The invention relates to the technical field of aviation turbine disk manufacturing, and in particular to the application of a dual-channel powder feeding process in the preparation of aviation engine turbine disk blanks. Background Art

[0002] The turbine disk of an aircraft engine is one of the core hot end components of the engine. It operates under multiple extreme conditions such as high temperature, high speed and complex stress, and the comprehensive performance requirements of the material are extremely stringent. Different areas of the turbine disk, such as the disk core, transition zone and disk rim, have different requirements for their structure and performance, such as strength, toughness, fatigue resistance, creep resistance and oxidation resistance, due to the different temperatures and stress states they are subjected to. For example, the disk core area usually requires the material to have high yield strength, good low-cycle fatigue performance and fracture toughness to withstand the cyclic loads during startup and shutdown; while the disk rim area requires the material to have excellent creep resistance, long-term strength and structural stability to withstand the challenges brought by long-term high-temperature operation.

[0003] Traditional turbine disk manufacturing processes, such as integral forging or powder metallurgy hot isostatic pressing, typically utilize a single-component, high-temperature alloy material for the overall fabrication. While mature, this approach has limitations in meeting the specific performance requirements of each turbine disk region. This often compromises the performance of one region while sacrificing that of another, making it difficult to optimally match material properties across different regions. This, in turn, limits further improvements in overall turbine disk performance and the engine's thrust-to-weight ratio.

[0004] In recent years, additive manufacturing (AM) technology, particularly powder-feeding directed energy deposition (DED) technologies such as arc AM and laser melting deposition, has provided a new approach for the fabrication of high-performance turbine disks due to its unique advantages in forming complex structures, providing material design freedom, and achieving near-net-shape results. AM technology theoretically enables the creation of gradient distributions of material composition and microstructure, enabling the fabrication of functionally graded materials (FGM) turbine disks that meet specific performance requirements across different regions.

[0005] However, in practical applications, existing single-channel powder feeding additive manufacturing processes have limited capabilities for precisely controlling the gradient ratio of multi-component, multi-ingredient powders, making it difficult to flexibly and accurately achieve a smooth transition and precise control of the material composition in different regions of the turbine disk. Furthermore, the rapid melting and solidification characteristics of the additive manufacturing process can easily lead to coarse deposited material structures, metallurgical defects such as element segregation, internal porosity, or lack of fusion. These defects can significantly affect the mechanical properties and service reliability of the material. Although subsequent heat treatment processes can improve the structure and performance to a certain extent, eliminating all native defects and obtaining the ideal fine and uniform grain structure remains a challenge. Summary of the Invention

[0006] The present invention discloses the application of a dual-channel powder feeding process in the preparation of a turbine disk blank for an aero-engine. A turbine disk blank is prepared, and precise gradient control of material composition in different areas of the turbine disk is achieved. The microstructure of the deposited material can be effectively improved and regulated during the manufacturing process, reducing metallurgical defects, and solving the technical problems of insufficient performance, short life and low reliability of aero-engine turbine disks in the prior art.

[0007] The present invention seeks to protect the application of a dual-channel powder feeding process in the preparation of a turbine disk blank for an aero-engine. The process uses an arc powder feeding additive process to deposit high-temperature alloy powder in a gradient ratio through a dual-channel system, forming a material gradient distribution in the disk center, transition and disk edge areas. At the same time, a synchronous micro-forging process is used to apply dynamic mechanical deformation to the new deposited layer in a high-temperature plastic state. The obtained turbine disk blank is subjected to hot isostatic pressing treatment, high-temperature homogenization annealing is performed in a vacuum furnace, and finally, the turbine disk blank is obtained through solid solution treatment and aging treatment.

[0008] As a further improvement of the present invention, the following steps are included:

[0009] Arc powder feeding additive process: High-temperature alloy powder is deposited in a gradient ratio through a dual-channel powder feeding system. This includes adding material to the disk center, transition zone, and rim. Gradient material distribution is achieved by adjusting the powder feeding rates of the two powder feeding channels.

[0010] The general parameters of the arc powder feeding additive process are powder feeding speed of the mixed powder channel, arc current, arc voltage, deposition layer thickness, interlayer residence time and protective atmosphere;

[0011] S2. Synchronous micro-forging process: Mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state while the material is being accumulated. Dynamic extrusion or rolling is applied to the newly deposited layer through a micro-rolling forging mechanism.

[0012] S3. Hot Isostatic Pressing (HIPPING) heat treatment process: Hot isostatic pressing (HIPPING) is performed on the turbine disk blank after additive manufacturing and simultaneous micro-forging.

[0013] S4. Homogenization: The hot isostatically pressed blank is subjected to high-temperature homogenization annealing in a vacuum furnace;

[0014] S5. Solution + aging heat treatment process: The homogenized blank is subjected to solution treatment and aging treatment in a vacuum furnace to obtain a turbine disk blank.

[0015] As a further improvement of the present invention, in S1, the gradient ratio of the additive in the center region of the disk is as follows: the powder feeding rate of channel 1 is set to 2.5-4.0 m / min, and the powder feeding rate of channel 2 is set to 0.5-1.5 m / min or 0 m / min;

[0016] The gradient ratio of the additive in the transition zone is as follows: as the additive path moves from the center of the disk to the edge of the disk, the powder feeding rate of channel 1 gradually decreases, while the powder feeding rate of channel 2 gradually increases;

[0017] The gradient ratio of the additive in the disk edge area is: set the powder feeding rate of channel one to 0.5-1.5m / min or 0m / min, and set the powder feeding rate of channel two to 2.5-4.0m / min.

[0018] As a further improvement of the present invention, in S1, the general parameters of the arc powder feeding additive process are specifically:

[0019] Mixed powder channel powder feeding speed: 1~5m / min;

[0020] Arc current: 100~300A;

[0021] Arc voltage: 15~25V;

[0022] Sediment layer thickness: 0.5~2mm;

[0023] Interlayer residence time: 10~30s;

[0024] Protective atmosphere: high-purity Ar gas, flow rate 10-25L / min, temperature controlled at -15~0℃.

[0025] As a further improvement of the present invention, in S2, the parameters for applying mechanical deformation are:

[0026] Forging timing: immediately after each layer or layers of material solidify and are at a high temperature of 800-1150℃;

[0027] Forging method: applying unidirectional or multidirectional dynamic extrusion or rolling to the newly deposited layer through a micro-rolling forging mechanism;

[0028] Forging pressure: 50~200MPa;

[0029] Forging mechanism moving speed: 1~5m / min;

[0030] Reduction rate: 5%~20%.

[0031] As a further improvement of the present invention, in S3, the parameters of the hot isostatic pressing treatment are:

[0032] Pressure: 100~150MPa;

[0033] Temperature: 1000~1200℃;

[0034] Keep warm time: 2~4 hours;

[0035] Heating and cooling rate: 3-10℃ / min.

[0036] As a further improvement of the present invention, in S4, the parameters of the high temperature homogenization annealing are:

[0037] Processing environment: vacuum degree is better than 5×10⁻²Pa, and it is recommended to reach 1×10⁻³Pa or higher;

[0038] Temperature: 900~1110℃;

[0039] Keep warm time: 1~3 hours;

[0040] Cooling method: furnace cooling or controlled rate cooling.

[0041] As a further improvement of the present invention, in S4, the parameters of the solution treatment are: temperature 800-1000° C., holding time 2-4 hours, and cooling method is oil quenching, gas quenching or water quenching.

[0042] As a further improvement of the present invention, in S4, the parameters of the aging treatment are: temperature 600-700° C., holding time 8-16 hours, and cooling method is air cooling or furnace cooling.

[0043] As a further improvement of the present invention, the present invention specifically comprises the following steps:

[0044] S1. Arc powder feeding additive process: High-temperature alloy powder is deposited in a gradient ratio through a dual-channel powder feeding system. Specifically:

[0045] Additive manufacturing in the center of the disk: Set the powder feeding rate of channel 1 to 2.5-4.0 m / min, and the powder feeding rate of channel 2 to 0.5-1.5 m / min or 0 m / min;

[0046] Additive in the transition zone: As the additive path moves from the center of the disk to the edge, the powder feeding rate of channel 1 gradually decreases, while the powder feeding rate of channel 2 gradually increases;

[0047] Additive manufacturing in the disk edge area: Set the powder feeding rate of channel 1 to 0.5-1.5m / min or 0m / min, and set the powder feeding rate of channel 2 to 2.5-4.0m / min;

[0048] The general parameters of the arc powder feeding additive process are:

[0049] Mixed powder channel powder feeding speed: 1~5m / min;

[0050] Arc current: 100~300A;

[0051] Arc voltage: 15~25V;

[0052] Sediment layer thickness: 0.5~2mm;

[0053] Interlayer residence time: 10~30s;

[0054] Protective atmosphere: high-purity Ar gas, flow rate 10-25L / min, temperature controlled at -15~0℃;

[0055] S2. Synchronous micro-forging process: Mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state while the material is being accumulated. Specifically:

[0056] Forging timing: immediately after each layer or layers of material solidify and are at a high temperature of 800-1150℃;

[0057] Forging method: applying unidirectional or multidirectional dynamic extrusion or rolling to the newly deposited layer through a micro-rolling forging mechanism;

[0058] Forging pressure: 50~200MPa;

[0059] Forging mechanism moving speed: 1~5m / min;

[0060] Reduction rate: 5% to 20%;

[0061] S3. Hot isostatic pressing heat treatment process: The turbine disk blank that has completed additive manufacturing and simultaneous micro-forging is subjected to hot isostatic pressing treatment. The specific parameters are:

[0062] Pressure: 100~150MPa;

[0063] Temperature: 1000~1200℃;

[0064] Keep warm time: 2~4 hours;

[0065] Heating and cooling rate: 3-10℃ / min;

[0066] S4. Homogenization treatment: The hot isostatic pressed blank is subjected to high temperature homogenization annealing in a vacuum furnace. The specific parameters are:

[0067] Processing environment: vacuum degree is better than 5×10⁻²Pa, and it is recommended to reach 1×10⁻³Pa or higher;

[0068] Temperature: 900~1110℃;

[0069] Keep warm time: 1~3 hours;

[0070] Cooling method: furnace cooling or controlled rate cooling;

[0071] S5. Solution + Aging Heat Treatment Process: In a vacuum furnace with a vacuum degree of ≤1×10⁻³Pa, the homogenized blank is subjected to standard solution treatment and aging treatment to obtain a turbine disk blank. Specifically:

[0072] Solution treatment: temperature 800~1000℃, holding time 2~4 hours, cooling method adopts oil quenching, gas quenching or water quenching;

[0073] Aging treatment: temperature 600~700℃, holding time 8~16 hours, cooling method adopts air cooling or furnace cooling.

[0074] The present invention has the following beneficial effects:

[0075] The present invention provides an application of a dual-channel powder feeding process in the preparation of aero-engine turbine disk blanks. The dual-channel powder feeding system is used to combine gradient ratio deposition, synchronous micro-forging process, low-temperature protective atmosphere and heat treatment process to solve the technical problem of insufficient performance of turbine disks prepared by traditional processes.

[0076] (1) The dual-channel powder feeding system used in the present invention, combined with a synchronous micro-forging process, achieves effective grain refinement and microstructure optimization. Mechanical deformation breaks up as-cast dendrites, promotes the recrystallization process, forms a fine and uniform grain structure, increases the grain boundary area, effectively hinders dislocation movement, and improves material strength. Experimental data show that the room temperature tensile strength and yield strength of Example 1 using this process are increased by approximately 12% and 15%, respectively, compared to Comparative Example 1, and the high-temperature tensile strength and yield strength are increased by approximately 14% and 18%, respectively.

[0077] (2) The dual-channel powder feeding system of the present invention achieves gradient ratio deposition of two high-temperature alloys, forming a composition gradient distribution in different parts of the turbine disc, giving full play to the complementary advantages of the two alloys. The gradient transition design avoids sudden changes in interface composition, reduces interface stress concentration, and improves overall performance. Experiments show that compared with Comparative Example 2, the endurance life of Example 1 at 650℃ / 650MPa and 760℃ / 450MPa conditions is increased by 33% and 50%, respectively, the fatigue life is increased by 39% and 50%, the crack growth rate is reduced by 22%, and the thermal fatigue life is increased by 42%.

[0078] (3) The present invention utilizes a low-temperature protective atmosphere and a high-vacuum processing environment to effectively inhibit oxidation reactions during the material preparation process. By reducing the oxygen partial pressure and active oxygen content in the environment, the initial oxide content within the material is reduced, thereby improving the material's purity and oxidation resistance. Experimental data show that the weight gain of Example 1 after oxidation at 900°C / 100h is approximately 28% lower than that of Comparative Example 1 and approximately 63% lower than that of Comparative Example 3.

[0079] (4) The present invention utilizes a combination of hot isostatic pressing, homogenization, and solution + aging heat treatments to optimize the material's microstructure and phase composition. In particular, by controlling the size, morphology, and distribution of the γ′ phase, the thermal stability and high-temperature performance of the material are improved. Experiments show that the hardness of Example 1 decreases by approximately 5% after heat exposure at 900°C for 500 hours, while that of Comparative Example 1 decreases by approximately 9% and that of Comparative Example 3 by approximately 12%.

[0080] (5) The present invention achieves a comprehensive improvement in the comprehensive performance of turbine disk materials through the synergistic effect of the above-mentioned processes. Compared with Comparative Example 1, Example 1 has an endurance life increased by 78% and 80%, a fatigue life increased by 67% and 80%, a crack growth rate decreased by 30%, and a thermal fatigue life increased by 63%. Compared with Comparative Example 3, Example 1 has an endurance life increased by 100% and 112%, a fatigue life increased by 92% and 125%, a crack growth rate decreased by 36%, and a thermal fatigue life increased by 77%.

[0081] (6) The present invention significantly improves the reliability, safety and service life of aircraft engine turbine disks by improving key properties of turbine disk materials such as high temperature strength, fatigue performance, crack propagation resistance, thermal fatigue life and oxidation resistance. At the same time, it provides technical support for the weight reduction design of turbine disks and the improvement of engine thrust-to-weight ratio, and has important engineering application value. BRIEF DESCRIPTION OF THE DRAWINGS

[0082] Figure 1 Schematic diagram of the dual-channel powder feeding process and synchronous micro-forging process in Example 1;

[0083] Figure 2This is a schematic diagram of the dual-channel powder feeding system of Example 1, wherein powder feeding port 1 is channel 1, powder feeding port 2 is channel 2, and the powder feeding port is a mixed powder channel powder feeding channel;

[0084] Figure 3 This is a schematic diagram of the powder feeding starting point and powder feeding direction of Example 1, wherein the powder feeding starting point is the center of the disk and the powder feeding direction is counterclockwise;

[0085] Figure 4 Schematic diagram of the micro-rolling and forging mechanism of Example 1. DETAILED DESCRIPTION

[0086] The technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0087] Example 1: A turbine disc blank was produced by applying a dual-channel powder feeding process (the schematic diagram of the dual-channel powder feeding process and micro-forging process of this embodiment is shown in FIG. Figure 1 shown).

[0088] First, the arc powder feeding process is carried out, and the high-temperature alloy powder is fed through a dual-channel powder feeding system (schematic diagram as shown in the figure). Figure 2 As shown in the figure, gradient deposition is performed, where the powder in channel 1 is GH4169 high-temperature alloy powder with a particle size of 45-105μm, and the powder in channel 2 is GH4738 high-temperature alloy powder with a particle size of 53-150μm. When adding material in the center area of ​​the disk, the powder feeding rate of channel 1 is set to 3.5m / min, and the powder feeding rate of channel 2 is set to 0.8m / min. When adding material in the transition area, as the additive path moves from the center of the disk to the edge of the disk (the schematic diagram of the powder feeding starting point and powder feeding direction is shown in the figure), the powder feeding rate of channel 1 is set to 3.5m / min, and the powder feeding rate of channel 2 is set to 0.8m / min. Figure 3 (As shown), the powder feed rate in channel 1 gradually decreases to 1.5 m / min, while the powder feed rate in channel 2 gradually increases to 2.8 m / min. When adding material to the disk rim, the powder feed rate in channel 1 is set to 0.8 m / min, and the powder feed rate in channel 2 is set to 3.5 m / min. General parameters for the arc powder feeding additive process are: a mixed powder channel feed rate of 4.3 m / min, an arc current of 180 A, an arc voltage of 20 V, a deposited layer thickness of 1.2 mm, an interlayer dwell time of 15 seconds, a protective atmosphere of high-purity Ar gas at a flow rate of 18 L / min, and a temperature control of -10°C.

[0089] Then, a synchronous micro-forging process is carried out. While the material is being accumulated, mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state. The forging time is selected to be carried out immediately when each layer of material is solidified and at a high temperature of 950°C. The forging method is carried out by a micro-rolling forging mechanism (schematic diagram as shown in the figure). Figure 4 As shown in the figure, bidirectional dynamic extrusion is applied to the new deposited layer, the forging pressure is 120 MPa, the moving speed of the forging mechanism is 3 m / min, and the reduction rate is 12%.

[0090] Then, a hot isostatic pressing heat treatment process is carried out on the turbine disk blank that has completed additive manufacturing and synchronous micro-forging. The specific parameters are: pressure of 125MPa, temperature of 1100℃, holding time of 3 hours, and heating and cooling rate of 5℃ / min.

[0091] Then, homogenization treatment is carried out, and the hot isostatic pressing blank is subjected to high-temperature homogenization annealing in a vacuum furnace. The treatment environment is a vacuum degree of 1×10⁻³Pa, the temperature is 1050℃, the holding time is 2 hours, and the cooling method adopts controlled rate cooling with a cooling rate of 3℃ / min.

[0092] Finally, a solution + aging heat treatment process is carried out. In a vacuum furnace with a vacuum degree of 1×10⁻³Pa, the billet after homogenization treatment is subjected to standard solution treatment and aging treatment. The solution treatment temperature is 950℃, the holding time is 3 hours, and the cooling method is oil quenching; the aging treatment temperature is 650℃, the holding time is 12 hours, and the cooling method is air cooling to obtain the turbine disk blank.

[0093] Example 2: A turbine disk blank was produced by using a dual-channel powder feeding process.

[0094] First, an arc powder feeding additive process is carried out, where high-temperature alloy powder is deposited in a gradient ratio through a dual-channel powder feeding system. The powder in channel one is GH4169 high-temperature alloy powder with a particle size of 40-100μm, and the powder in channel two is GH4738 high-temperature alloy powder with a particle size of 50-145μm. When adding material in the center of the disk, the powder feeding rate of channel one is set to 2.8m / min, and the powder feeding rate of channel two is set to 0.5m / min. When adding material in the transition area, as the additive path moves from the center of the disk to the edge of the disk, the powder feeding rate of channel one gradually decreases to 1.2m / min, and the powder feeding rate of channel two gradually increases to 2.1m / min. When adding material in the edge of the disk, the powder feeding rate of channel one is set to 0.5m / min, and the powder feeding rate of channel two is set to 2.8m / min. The general parameters of the arc powder feeding additive process are: the powder feeding speed of the mixed powder channel is 3.3m / min, the arc current is 150A, the arc voltage is 18V, the deposition layer thickness is 1.0mm, the interlayer residence time is 20s, the protective atmosphere is high-purity Ar gas, the flow rate is 15L / min, and the temperature is controlled at -12℃.

[0095] Subsequently, a synchronous micro-forging process is carried out, in which mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state while the material is being accumulated. The forging is carried out immediately after every two layers of material solidify and are at a high temperature of 900°C. The forging method is to apply unidirectional dynamic rolling to the newly deposited layer through a micro-rolling forging mechanism. The forging pressure is 100 MPa, the forging mechanism movement rate is 2 m / min, and the reduction rate is 10%.

[0096] Then, a hot isostatic pressing heat treatment process is carried out on the turbine disk blank that has completed additive manufacturing and synchronous micro-forging. The specific parameters are: pressure of 110 MPa, temperature of 1050°C, holding time of 2.5 hours, and heating and cooling rate of 4°C / min.

[0097] Then, homogenization treatment is carried out, and the hot isostatic pressing blank is subjected to high-temperature homogenization annealing in a vacuum furnace. The treatment environment is a vacuum degree of 2×10⁻³Pa, the temperature is 1000℃, the holding time is 1.5 hours, and the cooling method is furnace cooling.

[0098] Finally, a solution + aging heat treatment process is carried out. In a vacuum furnace with a vacuum degree of 1×10⁻³Pa, the billet after homogenization treatment is subjected to standard solution treatment and aging treatment. The solution treatment temperature is 900℃, the holding time is 2.5 hours, and the cooling method is gas quenching; the aging treatment temperature is 630℃, the holding time is 10 hours, and the cooling method is furnace cooling to obtain the turbine disk blank.

[0099] Example 3: A turbine disk blank was produced by applying a dual-channel powder feeding process.

[0100] First, an arc powder feeding additive process is performed, where high-temperature alloy powder is deposited in a gradient ratio through a dual-channel powder feeding system. Channel 1 powder is GH4169 high-temperature alloy powder with a particle size of 50-110μm, and channel 2 powder is GH4738 high-temperature alloy powder with a particle size of 55-155μm. When adding material in the center of the disk, the powder feeding rate of channel 1 is set to 4.0m / min, and the powder feeding rate of channel 2 is set to 0m / min. When adding material in the transition area, as the additive path moves from the center of the disk to the edge of the disk, the powder feeding rate of channel 1 gradually decreases to 2.0m / min, and the powder feeding rate of channel 2 gradually increases to 2.0m / min. When adding material in the edge of the disk, the powder feeding rate of channel 1 is set to 0m / min, and the powder feeding rate of channel 2 is set to 4.0m / min. The general parameters of the arc powder feeding additive process are: the powder feeding speed of the mixed powder channel is 4.0m / min, the arc current is 200A, the arc voltage is 22V, the deposition layer thickness is 1.5mm, the interlayer residence time is 25s, the protective atmosphere is high-purity Ar gas, the flow rate is 20L / min, and the temperature is controlled at -8℃.

[0101] Subsequently, a synchronous micro-forging process is carried out, in which mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state while the material is accumulating. The forging timing is selected to be carried out immediately when each layer of material is solidified and at a high temperature of 1000°C. The forging method is to apply multi-directional dynamic extrusion to the newly deposited layer through a micro-rolling forging mechanism. The forging pressure is 150MPa, the forging mechanism movement rate is 4m / min, and the reduction rate is 15%.

[0102] Then, a hot isostatic pressing heat treatment process is carried out on the turbine disk blank that has completed additive manufacturing and synchronous micro-forging. The specific parameters are: pressure of 140MPa, temperature of 1150℃, holding time of 3.5 hours, and heating and cooling rate of 7℃ / min.

[0103] Then the homogenization treatment is carried out, and the hot isostatic pressing blank is subjected to high temperature homogenization annealing in a vacuum furnace with a vacuum degree of 5×10⁻ 4 Pa, the temperature is 1100℃, the holding time is 2.5 hours, the cooling method adopts controlled rate cooling, and the cooling rate is 5℃ / min.

[0104] Finally, the solid solution + aging heat treatment process is carried out at a vacuum degree of 5×10⁻ 4 In a vacuum furnace at Pa, the billet after homogenization treatment was subjected to standard solution treatment and aging treatment. The solution treatment temperature was 980°C, the holding time was 3.5 hours, and the cooling method was oil quenching; the aging treatment temperature was 670°C, the holding time was 14 hours, and the cooling method was air cooling to obtain a turbine disk blank.

[0105] Example 4: A turbine disk blank was produced by applying a dual-channel powder feeding process.

[0106] First, an arc powder feeding additive process is carried out, where high-temperature alloy powder is deposited in a gradient ratio through a dual-channel powder feeding system. The powder in channel one is GH4169 high-temperature alloy powder with a particle size of 48-108μm, and the powder in channel two is GH4738 high-temperature alloy powder with a particle size of 52-148μm. When adding material in the center of the disk, the powder feeding rate of channel one is set to 2.5m / min, and the powder feeding rate of channel two is set to 1.0m / min. When adding material in the transition area, as the additive path moves from the center of the disk to the edge of the disk, the powder feeding rate of channel one gradually decreases to 1.8m / min, and the powder feeding rate of channel two gradually increases to 1.8m / min. When adding material in the edge of the disk, the powder feeding rate of channel one is set to 1.0m / min, and the powder feeding rate of channel two is set to 2.5m / min. The general parameters of the arc powder feeding additive process are: the powder feeding speed of the mixed powder channel is 3.5m / min, the arc current is 160A, the arc voltage is 19V, the deposition layer thickness is 0.8mm, the interlayer residence time is 18s, the protective atmosphere is high-purity Ar gas, the flow rate is 16L / min, and the temperature is controlled at -15℃.

[0107] Subsequently, a synchronous micro-forging process is carried out, in which mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state while the material is being accumulated. The forging is carried out immediately after every three layers of material are solidified and at a high temperature of 850°C. The forging method is to apply unidirectional dynamic extrusion to the newly deposited layer through a micro-rolling forging mechanism. The forging pressure is 80 MPa, the forging mechanism movement rate is 1.5 m / min, and the reduction rate is 8%.

[0108] Then, a hot isostatic pressing heat treatment process is carried out on the turbine disk blank that has completed additive manufacturing and synchronous micro-forging. The specific parameters are: pressure of 105MPa, temperature of 1020℃, holding time of 2 hours, and heating and cooling rate of 3.5℃ / min.

[0109] Then, homogenization treatment is carried out, and the hot isostatic pressing blank is subjected to high-temperature homogenization annealing in a vacuum furnace. The treatment environment is a vacuum degree of 3×10⁻³Pa, a temperature of 950℃, a holding time of 1 hour, and a cooling method of furnace cooling.

[0110] Finally, a solution + aging heat treatment process is carried out. In a vacuum furnace with a vacuum degree of 3×10⁻³Pa, the billet after homogenization treatment is subjected to standard solution treatment and aging treatment. The solution treatment temperature is 850℃, the holding time is 2 hours, and the cooling method is gas quenching; the aging treatment temperature is 620℃, the holding time is 9 hours, and the cooling method is furnace cooling to obtain the turbine disk blank.

[0111] Example 5: A turbine disk blank was produced by applying a dual-channel powder feeding process.

[0112] First, an arc powder feeding additive process is carried out, where high-temperature alloy powder is deposited in a gradient ratio through a dual-channel powder feeding system. The powder in channel one is GH4169 high-temperature alloy powder with a particle size of 42-102μm, and the powder in channel two is GH4738 high-temperature alloy powder with a particle size of 54-152μm. When adding material in the center of the disk, the powder feeding rate of channel one is set to 3.2m / min, and the powder feeding rate of channel two is set to 1.5m / min. When adding material in the transition area, as the additive path moves from the center of the disk to the edge of the disk, the powder feeding rate of channel one gradually decreases to 2.3m / min, and the powder feeding rate of channel two gradually increases to 2.4m / min. When adding material in the edge of the disk, the powder feeding rate of channel one is set to 1.5m / min, and the powder feeding rate of channel two is set to 3.2m / min. The general parameters of the arc powder feeding additive process are: the powder feeding speed of the mixed powder channel is 4.7m / min, the arc current is 250A, the arc voltage is 23V, the deposition layer thickness is 1.8mm, the interlayer residence time is 30s, the protective atmosphere is high-purity Ar gas, the flow rate is 22L / min, and the temperature is controlled at -5℃.

[0113] Subsequently, a synchronous micro-forging process is carried out, in which mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state while the material is being accumulated. The forging is carried out immediately after every two layers of material solidify and are at a high temperature of 1100°C. The forging method is to apply multi-directional dynamic rolling to the newly deposited layer through a micro-rolling forging mechanism. The forging pressure is 180 MPa, the forging mechanism movement rate is 4.5 m / min, and the reduction rate is 18%.

[0114] Then, a hot isostatic pressing heat treatment process is carried out on the turbine disk blank that has completed additive manufacturing and synchronous micro-forging. The specific parameters are: pressure of 145MPa, temperature of 1180℃, holding time of 4 hours, and heating and cooling rate of 9℃ / min.

[0115] Then, homogenization treatment is carried out, and the hot isostatic pressing blank is subjected to high-temperature homogenization annealing in a vacuum furnace. The treatment environment is a vacuum degree of 1×10⁻³Pa, the temperature is 1080℃, the holding time is 3 hours, and the cooling method adopts controlled rate cooling with a cooling rate of 6℃ / min.

[0116] Finally, a solution + aging heat treatment process is carried out. In a vacuum furnace with a vacuum degree of 1×10⁻³Pa, the billet after homogenization treatment is subjected to standard solution treatment and aging treatment. The solution treatment temperature is 980℃, the holding time is 4 hours, and the cooling method is water quenching; the aging treatment temperature is 680℃, the holding time is 16 hours, and the cooling method is air cooling to obtain the turbine disk blank.

[0117] Comparative Example 1: A turbine disk blank was produced. Different from Example 1, this comparative example did not perform the synchronous micro-forging process, but directly performed the hot isostatic pressing heat treatment process.

[0118] First, an arc powder feeding additive process is carried out, where high-temperature alloy powder is deposited in a gradient ratio through a dual-channel powder feeding system. The powder in channel one is GH4169 high-temperature alloy powder with a particle size of 45-105μm, and the powder in channel two is GH4738 high-temperature alloy powder with a particle size of 53-150μm. When adding material in the center of the disk, the powder feeding rate of channel one is set to 3.5m / min, and the powder feeding rate of channel two is set to 0.8m / min. When adding material in the transition area, as the additive path moves from the center of the disk to the edge of the disk, the powder feeding rate of channel one gradually decreases to 1.5m / min, and the powder feeding rate of channel two gradually increases to 2.8m / min. When adding material in the edge of the disk, the powder feeding rate of channel one is set to 0.8m / min, and the powder feeding rate of channel two is set to 3.5m / min. The general parameters of the arc powder feeding additive process are: the powder feeding speed of the mixed powder channel is 4.3m / min, the arc current is 180A, the arc voltage is 20V, the deposition layer thickness is 1.2mm, the interlayer residence time is 15s, the protective atmosphere is high-purity Ar gas, the flow rate is 18L / min, and the temperature is controlled at -10℃.

[0119] The AM turbine disk blanks were hot isostatically pressed (HIP) at 125 MPa, 1100°C, a 3-hour hold, and a 5°C / min heating and cooling rate. Homogenization was then performed, followed by a high-temperature homogenization annealing in a vacuum furnace at a vacuum of 1 × 10⁻³ Pa, a temperature of 1050°C, a 2-hour hold, and controlled-rate cooling at a rate of 3°C / min.

[0120] Finally, a solution + aging heat treatment process is carried out. In a vacuum furnace with a vacuum degree of 1×10⁻³Pa, the billet after homogenization treatment is subjected to standard solution treatment and aging treatment. The solution treatment temperature is 950℃, the holding time is 3 hours, and the cooling method is oil quenching; the aging treatment temperature is 650℃, the holding time is 12 hours, and the cooling method is air cooling to obtain the turbine disk blank.

[0121] Comparative Example 2: A turbine disk blank was produced. The difference from Example 1 is that the dual-channel powder feeding system was replaced with a single-channel powder feeding system.

[0122] First, an arc powder feeding additive process was performed, depositing superalloy powder through a single-channel powder feeding system. A single GH4169 superalloy powder with a particle size of 45-105μm was used. The entire turbine disk was added at a powder feed rate of 3.5m / min. The general parameters for the arc powder feeding additive process were: a powder feed rate of 3.5m / min, an arc current of 180A, an arc voltage of 20V, a deposited layer thickness of 1.2mm, an interlayer dwell time of 15s, a protective atmosphere of high-purity Ar gas at a flow rate of 18L / min, and a temperature control of -10°C.

[0123] Subsequently, a synchronous micro-forging process is carried out, in which mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state while the material is being accumulated. The forging is carried out immediately when each layer of material is solidified and at a high temperature of 950°C. The forging method is to apply bidirectional dynamic extrusion to the newly deposited layer through a micro-rolling forging mechanism. The forging pressure is 120 MPa, the forging mechanism movement rate is 3 m / min, and the reduction rate is 12%.

[0124] Then, a hot isostatic pressing heat treatment process is carried out on the turbine disk blank that has completed additive manufacturing and synchronous micro-forging. The specific parameters are: pressure of 125MPa, temperature of 1100℃, holding time of 3 hours, and heating and cooling rate of 5℃ / min.

[0125] Then, homogenization treatment is carried out, and the hot isostatic pressing blank is subjected to high-temperature homogenization annealing in a vacuum furnace. The treatment environment is a vacuum degree of 1×10⁻³Pa, the temperature is 1050℃, the holding time is 2 hours, and the cooling method adopts controlled rate cooling with a cooling rate of 3℃ / min.

[0126] Finally, a solution + aging heat treatment process is carried out. In a vacuum furnace with a vacuum degree of 1×10⁻³Pa, the billet after homogenization treatment is subjected to standard solution treatment and aging treatment. The solution treatment temperature is 950℃, the holding time is 3 hours, and the cooling method is oil quenching; the aging treatment temperature is 650℃, the holding time is 12 hours, and the cooling method is air cooling to obtain the turbine disk blank.

[0127] Comparative Example 3: A turbine disk blank was produced. Compared with Example 1, Comparative Example 3 lacks the low-temperature protective atmosphere and high vacuum processing environment.

[0128] First, an arc powder feeding additive process is carried out, where high-temperature alloy powder is deposited in a gradient ratio through a dual-channel powder feeding system. The powder in channel one is GH4169 high-temperature alloy powder with a particle size of 45-105μm, and the powder in channel two is GH4738 high-temperature alloy powder with a particle size of 53-150μm. When adding material in the center of the disk, the powder feeding rate of channel one is set to 3.5m / min, and the powder feeding rate of channel two is set to 0.8m / min. When adding material in the transition area, as the additive path moves from the center of the disk to the edge of the disk, the powder feeding rate of channel one gradually decreases to 1.5m / min, and the powder feeding rate of channel two gradually increases to 2.8m / min. When adding material in the edge of the disk, the powder feeding rate of channel one is set to 0.8m / min, and the powder feeding rate of channel two is set to 3.5m / min. The general parameters of the arc powder feeding additive process are: the powder feeding speed of the mixed powder channel is 4.3m / min, the arc current is 180A, the arc voltage is 20V, the deposition layer thickness is 1.2mm, the interlayer residence time is 15s, and the protective atmosphere is ordinary Ar gas with a purity of 99.5%, a flow rate of 18L / min, and a temperature of 25°C.

[0129] Subsequently, a synchronous micro-forging process is carried out, in which mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state while the material is being accumulated. The forging is carried out immediately when each layer of material is solidified and at a high temperature of 950°C. The forging method is to apply bidirectional dynamic extrusion to the newly deposited layer through a micro-rolling forging mechanism. The forging pressure is 120 MPa, the forging mechanism movement rate is 3 m / min, and the reduction rate is 12%.

[0130] Then, a hot isostatic pressing heat treatment process is carried out on the turbine disk blank that has completed additive manufacturing and synchronous micro-forging. The specific parameters are: pressure of 125MPa, temperature of 1100℃, holding time of 3 hours, and heating and cooling rate of 5℃ / min.

[0131] Then, homogenization treatment is carried out, and the hot isostatic pressing blank is subjected to high-temperature homogenization annealing in a vacuum furnace. The treatment environment is a vacuum degree of 1×10⁻²Pa, the temperature is 1050℃, the holding time is 2 hours, and the cooling method adopts controlled rate cooling with a cooling rate of 3℃ / min.

[0132] Finally, a solution + aging heat treatment process is carried out. In a vacuum furnace with a vacuum degree of 1×10⁻²Pa, the billet after homogenization treatment is subjected to standard solution treatment and aging treatment. The solution treatment temperature is 950°C, the holding time is 3 hours, and the cooling method is oil quenching; the aging treatment temperature is 650°C, the holding time is 12 hours, and the cooling method is air cooling to obtain the turbine disk blank.

[0133] Performance testing

[0134] Test Method 1. Microstructure Analysis: Metallographic specimens were prepared from the turbine disk samples prepared in the Examples and Comparative Examples, each from the center, transition zone, and rim. The samples were first cut into 10 mm × 10 mm × 5 mm blocks and then subjected to a standard metallographic preparation procedure: coarse grinding (120-1200 grit sandpaper, in sequence), fine grinding (1.0 μm and 0.5 μm diamond suspension polishing), ultrasonic cleaning (10 minutes each in acetone and ethanol), and drying (30 minutes in a 60°C oven). The samples were then etched using an etching solution (10 ml HNO₃ + 30 ml HCl + 40 ml H₂O) at room temperature for 30-60 seconds, followed by further ultrasonic cleaning and drying. Grain morphology and size were observed using a ZEISS Axio Imager M2m metallographic microscope at 100×, 500×, and 1000× magnifications. Grain size statistics were analyzed using Image-Pro Plus 6.0 software. Ten randomly selected fields of view were used for each sample, and at least 200 grains were measured. Microstructural features were observed using a FEI Quanta 650 FEG scanning electron microscope (SEM) at an accelerating voltage of 20 kV and a working distance of 10 mm. The morphology and distribution of the precipitated phases were observed using a JEOL JEM-2100F transmission electron microscope (TEM). Thin film samples were prepared using a double-spray electrolytic polishing technique with an electrolyte of 10% perchloric acid and 90% ethanol at a temperature of -30°C, a voltage of 20 V, a current of 30 mA, and a polishing time of 60 to 90 seconds.

[0135] Test method 2: Mechanical properties test method.

[0136] Tensile Properties Testing: In accordance with GB / T 228.1-2010, standard tensile specimens with a gauge length of 25 mm and a diameter of 5 mm were machined from the core, transition zone, and rim of the turbine disks prepared in the Examples and Comparative Examples. Tensile tests were conducted at room temperature (25°C), medium temperature (650°C), and high temperature (850°C) using an MTS810 materials testing system. For high-temperature testing, the specimens were first heated to the target temperature and held for 30 minutes to ensure temperature uniformity. Tensile testing was then performed at a rate of 1 mm / min until the specimens fractured. The tensile strength (σb), yield strength (σ0.2), elongation (δ), and reduction of area (ψ) were recorded. Three replicates were tested for each condition, and the average result was taken as the final result.

[0137] Durability Testing: In accordance with GB / T 2039-2012, standard durability specimens were machined from the core, transition zone, and rim of the turbine disks prepared in the Examples and Comparative Examples. The specimens had a gauge length of 25 mm and a diameter of 5 mm. Durability testing was conducted using an RDL-50 high-temperature creep testing machine at temperatures of 650°C and 760°C, with stress levels of 650 MPa and 450 MPa, respectively. The sample break time and elongation at break were recorded. Three replicates were tested for each condition, and the average result was taken as the final result.

[0138] Fatigue Performance Testing: According to GB / T 3075-2008, standard high-cycle fatigue specimens were machined from the core, transition zone, and rim of the turbine disks prepared in the Examples and Comparative Examples. The specimens had a gauge length of 12 mm and a diameter of 6 mm. High-cycle fatigue testing was conducted at room temperature (25°C) and high temperature (650°C) using an MTS810 fatigue testing system. Axial loading was employed, with a stress ratio R = 0.1, a frequency of 20 Hz (room temperature) and 10 Hz (high temperature), and a maximum stress level of 800 MPa. The number of cycles to fracture was recorded. Five replicates were tested for each condition, and the logarithmic mean was used as the final result.

[0139] Crack Growth Rate Testing: CT specimens with a thickness of 12.5 mm were machined from the core, transition zone, and rim of turbine disks prepared in the Examples and Comparative Examples according to GB / T 6398-2000. Crack growth rate tests were conducted at room temperature (25°C) and elevated temperature (650°C) using an MTS 810 fatigue crack growth test system. Constant amplitude loading was used, with a stress ratio R = 0.1 and a frequency of 10 Hz (room temperature) and 5 Hz (elevated temperature). Crack length was monitored in real time using the DC potential drop method. Based on the test data, the crack growth rate (da / dN) was calculated for different stress intensity factor (ΔK) ranges.

[0140] Test method 3: High temperature performance test method

[0141] Thermal fatigue performance test: Thermal fatigue specimens with dimensions of 100mm×10mm×3mm were processed from the rim area of ​​the turbine disk prepared in the examples and comparative examples. The thermal fatigue test was carried out using a self-developed thermal fatigue test device with a temperature cycle range of 100-750°C, a heating rate of 50°C / s, a cooling rate of 30°C / s, a high temperature holding time of 60s, and a low temperature holding time of 30s. The surface cracks of the sample were checked every 100 cycles, and the crack length and density were observed and recorded using an optical microscope. The test continued until a through crack with a length of more than 2mm appeared on the surface of the sample, and the number of cycles at this time was recorded as the thermal fatigue life.

[0142] Oxidation resistance test: Oxidation specimens measuring 20 mm × 10 mm × 2 mm were processed from the rim area of ​​the turbine disk prepared in the examples and comparative examples. Isothermal oxidation tests were performed using a high-temperature box-type resistance furnace at 900°C for 100 hours. Samples were removed every 10 hours, cooled to room temperature, and the sample mass was measured using a precision electronic balance (accuracy 0.01 mg). Based on the test data, the oxidation weight gain per unit area was calculated, and the oxidation kinetics curve was fitted. After the test, the surface oxide film morphology and cross-sectional structure of the sample were observed using a SEM, and the oxide composition was analyzed using an energy dispersive spectrometer (EDS).

[0143] Thermal Stability Testing: Turbine disk samples prepared from the Examples and Comparative Examples were subjected to prolonged heat exposure (500 hours) at 900°C. Hardness and microstructural changes before and after the exposure were measured. Vickers hardness was measured using an HVS-1000 digital microhardness tester with a load of 1 kg and a hold time of 15 seconds. Ten randomly selected points on each sample were measured, and the average value was calculated.

[0144] Test results table

[0145] Table 1. Grain size statistics (μm)

[0146] Sample number Center area transition zone Edge area Example 1 35±3 38±4 42±3 Example 2 38±4 40±3 45±4 Example 3 32±2 35±3 40±3 Example 4 40±3 42±4 47±4 Example 5 30±2 33±3 38±2 Comparative Example 1 48±5 52±6 58±5 Comparative Example 2 36±4 45±5 55±6 Comparative Example 3 42±4 45±5 50±5

[0147] Table 2. Statistical results of γ' phase precipitates

[0148] Sample number Center area Edge area Size (nm) Volume fraction (%) Size (nm) Volume fraction (%) Example 1 25±5 12±2 45±8 25±3 Example 2 28±6 10±2 48±7 23±3 Example 3 22±4 14±2 42±6 28±3 Example 4 30±6 9±2 50±8 22±3 Example 5 20±4 15±2 40±5 30±3 Comparative Example 1 32±8 11±3 55±10 22±4 Comparative Example 2 26±5 12±2 28±6 13±2 Comparative Example 3 35±8 10±3 60±12 18±4

[0149] Table 3. Room temperature tensile properties test data

[0150] Sample number Tensile strength (MPa) Yield strength (MPa) Elongation (%) Sectional shrinkage (%) Example 1 1320±20 1050±15 22±2 25±2 Example 2 1280±25 1020±20 24±2 28±3 Example 3 1350±15 1080±15 20±2 23±2 Example 4 1250±25 980±20 26±3 30±3 Example 5 1380±15 1100±10 19±2 22±2 Comparative Example 1 1160±30 890±25 18±3 20±3 Comparative Example 2 1220±25 950±20 21±2 24±2 Comparative Example 3 1200±30 920±25 16±3 18±3

[0151] Table 4.650℃ high temperature tensile properties test data

[0152] Sample number Tensile strength (MPa) Yield strength (MPa) Elongation (%) Sectional shrinkage (%) Example 1 1050±20 850±15 18±2 20±2 Example 2 1020±25 820±20 20±2 22±2 Example 3 1080±15 880±15 16±2 18±2 Example 4 980±25 780±20 22±2 24±2 Example 5 1100±15 900±10 15±2 17±2 Comparative Example 1 920±30 720±25 14±3 16±3 Comparative Example 2 950±25 760±20 17±2 19±2 Comparative Example 3 880±30 700±25 12±3 14±3

[0153] Table 5.650℃ / 650MPa endurance performance test data

[0154] Sample number Break time (h) Elongation at break (%) Example 1 320±20 15±2 Example 2 280±25 18±2 Example 3 350±15 13±2 Example 4 250±25 20±2 Example 5 380±15 12±2 Comparative Example 1 180±30 22±3 Comparative Example 2 240±25 16±2 Comparative Example 3 160±30 25±3

[0155] Table 6.760℃ / 450MPa endurance performance test data

[0156] Sample number Break time (h) Elongation at break (%) Example 1 180±15 12±2 Example 2 160±20 14±2 Example 3 200±10 10±1 Example 4 140±20 16±2 Example 5 220±10 9±1 Comparative Example 1 100±25 18±3 Comparative Example 2 120±20 15±2 Comparative Example 3 85±25 20±3

[0157] Table 7. Room temperature high cycle fatigue test data (800MPa, R=0.1)

[0158] Sample number Fatigue life (number of cycles) Example 1 <![CDATA[2.5×10 5 ±0.3×10 5 ]]> Example 2 <![CDATA[2.2×10 5 ±0.4×10 5 ]]> Example 3 <![CDATA[2.8×10 5 ±0.2×10 5 ]]> Example 4 <![CDATA[2.0×10 5 ±0.4×10 5 <!-- 12 -->]]> Example 5 <![CDATA[3.0×10 5 ±0.2×10 5 ]]> Comparative Example 1 <![CDATA[1.5×10 5 ±0.5×10 5 ]]> Comparative Example 2 <![CDATA[1.8×10 5 ±0.4×10 5 ]]> Comparative Example 3 <![CDATA[1.3×10 5 ±0.5×10 5 ]]>

[0159] Table 8.650℃ high cycle fatigue test data (800MPa, R=0.1)

[0160] Sample number Fatigue life (number of cycles) Example 1 <![CDATA[1.8×10 5 ±0.2×10 5 ]]> Example 2 <![CDATA[1.6×10 5 ±0.3×10 5 ]]> Example 3 <![CDATA[2.0×10 5 ±0.2×10 5 ]]> Example 4 <![CDATA[1.4×10 5 ±0.3×10 5 ]]> Example 5 <![CDATA[2.2×10 5 ±0.1×10 5 ]]> Comparative Example 1 <![CDATA[1.0×10 5 ±0.4×10 5 ]]> Comparative Example 2 <![CDATA[1.2×10 5 ±0.3×10 5 ]]> Comparative Example 3 <![CDATA[0.8×10 5 ±0.4×10 5 ]]>

[0161] Table 9. 650℃ crack growth rate test data (ΔK=20MPa·m^(1 / 2))

[0162] Sample number Crack growth rate (m / cycle) Example 1 <![CDATA[3.5×10⁻ 8 ±0.3×10⁻ 8 ]]> Example 2 <![CDATA[3.8×10⁻ 8 ±0.4×10⁻ 8 ]]> Example 3 <![CDATA[3.2×10⁻ 8 ±0.2×10⁻ 8 ]]> Example 4 <![CDATA[4.0×10⁻ 8 ±0.4×10⁻ 8 ]]> Example 5 <![CDATA[3.0×10⁻ 8 ±0.2×10⁻ 8 ]]> Comparative Example 1 <![CDATA[5.0×10⁻ 8 ±0.5×10⁻ 8 ]]> Comparative Example 2 <![CDATA[4.5×10⁻ 8 ±0.4×10⁻ 8 ]]> Comparative Example 3 <![CDATA[5.5×10⁻ 8 ±0.5×10⁻ 8 ]]>

[0163] Table 10. Thermal fatigue life test data (100-750℃ cycle)

[0164] Sample number Thermal fatigue life (number of cycles) Example 1 850±50 Example 2 780±60 Example 3 920±40 Example 4 720±60 Example 5 980±40 Comparative Example 1 520±80 Comparative Example 2 600±70 Comparative Example 3 480±80

[0165] Table 11. 900℃ / 100h oxidation weight gain test data

[0166] Sample number Oxidation weight gain (mg / cm²) Example 1 1.8±0.2 Example 2 2.0±0.2 Example 3 1.6±0.1 Example 4 2.2±0.2 Example 5 1.5±0.1 Comparative Example 1 2.5±0.3 Comparative Example 2 2.3±0.2 Comparative Example 3 4.8±0.4

[0167] Table 12. Hardness change rate after 900℃ / 500h heat exposure (%)

[0168] Sample number Hardness change rate (%) Example 1 -5±1 Example 2 -6±1 Example 3 -4±1 Example 4 -7±1 Example 5 -3±1 Comparative Example 1 -9±2 Comparative Example 2 -8±2 Comparative Example 3 -12±2

[0169] Data Analysis

[0170] As can be seen from Table 1, the grain size of Examples 1-5 is significantly smaller than that of Comparative Examples 1-3, especially the grain size of Comparative Example 1 is about 35% larger than that of Example 1. This is because the synchronous micro-forging process is adopted in the examples, and mechanical deformation is applied to the newly deposited layer while the material is being accumulated, which promotes dynamic recrystallization and refines the grains. Grain refinement not only improves the strength of the material, but also improves the plasticity and toughness of the material. Comparative Example 1 lacks a synchronous micro-forging process, resulting in coarse grains and uneven microstructure. Although Comparative Example 2 also adopts a synchronous micro-forging process, it lacks a dual-channel powder feeding system for gradient ratio deposition, resulting in coarse grains in the disc edge area. Although Comparative Example 3 adopts a dual-channel powder feeding system and a synchronous micro-forging process, it lacks a low-temperature protective atmosphere and a high vacuum processing environment, resulting in an increased degree of material oxidation, an increase in grain boundary oxides, and uneven grain growth, resulting in an even more uneven grain size distribution.

[0171] As can be seen from Table 2, the volume fraction of γ' phase precipitates in the disk rim region of Examples 1-5 is significantly higher than that of Comparative Example 2. This is because the examples use a dual-channel powder feeding system for gradient ratio deposition. This demonstrates that the dual-channel powder feeding system used in the present invention for gradient ratio deposition can effectively regulate the alloy composition and microstructure of different regions of the turbine disk. The GH4738 alloy has a higher composition in the disk rim region, and the volume fraction of γ' phase precipitates in the GH4738 alloy is higher than that in the GH4169 alloy, which is beneficial to improving the high-temperature performance of the disk rim region. Although Comparative Example 1 also adopts a dual-channel powder feeding system, the lack of a synchronous micro-forging process results in the γ' phase precipitates being larger in size, unevenly distributed, and with a volume fraction slightly lower than that of Example 1; Comparative Example 2 lacks a dual-channel powder feeding system for gradient ratio deposition, resulting in a lower volume fraction of γ' phase precipitates in the disk edge area and insufficient high-temperature performance; although Comparative Example 3 adopts a dual-channel powder feeding system and a synchronous micro-forging process, the lack of a low-temperature protective atmosphere and a high-vacuum processing environment results in an increased degree of material oxidation, inhibited γ' phase precipitation, a lower volume fraction than that of Example 1, and a larger size and uneven distribution.

[0172] As can be seen from Table 3, the room temperature tensile properties of Examples 1-5 are significantly better than those of Comparative Examples 1-3, which fully proves that the synchronous micro-forging process and dual-channel powder feeding system used in the present invention for gradient ratio deposition can effectively improve the strength of the material. The tensile strength and yield strength of Example 1 are approximately 12% and 15% higher than those of Comparative Example 1, respectively. This is because Example 1 uses a synchronous micro-forging process to refine the grains and improve the strength of the material. The elongation and cross-sectional shrinkage of Example 1 are also higher than those of Comparative Example 1, indicating that the plasticity of the material has also been improved. Although Comparative Example 2 also uses a synchronous micro-forging process, the lack of a dual-channel powder feeding system for gradient ratio deposition results in unbalanced material properties and overall performance is lower than that of Example 1; although Comparative Example 3 uses a dual-channel powder feeding system and a synchronous micro-forging process, the lack of a low-temperature protective atmosphere and a high vacuum processing environment results in an increased degree of material oxidation, an increase in internal oxides, and reduced material strength and plasticity.

[0173] As can be seen from Table 4, the high-temperature tensile properties of Examples 1-5 are also significantly better than those of Comparative Examples 1-3. The high-temperature tensile strength and yield strength of Example 1 are approximately 14% and 18% higher than those of Comparative Example 1, respectively. This is mainly because Example 1 uses a synchronous micro-forging process and a dual-channel powder feeding system for gradient ratio deposition, which optimizes the microstructure of the material and improves the high-temperature strength.

[0174] As can be seen from Tables 5 and 6, the durability of Examples 1-5 is significantly superior to that of Comparative Examples 1-3. The fracture times of Example 1 at 650°C / 650 MPa and 760°C / 450 MPa are approximately 78% and 80% longer than those of Comparative Example 1, respectively. This is because Example 1 employs a synchronous micro-forging process, which refines the grains, reduces grain boundary sliding, and improves the creep resistance of the material. Furthermore, the dual-channel powder feeding system for gradient deposition results in a higher composition of the GH4738 alloy in the disc rim area. The high-temperature performance of GH4738 alloy is superior to that of GH4169 alloy, further improving the durability of the material. Although Comparative Example 2 also employs a synchronous micro-forging process, the lack of a dual-channel powder feeding system for gradient deposition results in insufficient high-temperature performance in the disc rim area, resulting in lower durability than Example 1. Although Comparative Example 3 employs a dual-channel powder feeding system and synchronous micro-forging process, the lack of a low-temperature protective atmosphere and a high-vacuum processing environment results in increased oxidation and an increase in internal oxides, which reduces the durability of the material.

[0175] As can be seen from Tables 7 and 8, the fatigue performance of Examples 1-5 is significantly superior to that of Comparative Examples 1-3. The room temperature and 650°C high-cycle fatigue life of Example 1 are approximately 67% and 80% longer, respectively, than those of Comparative Example 1. This is due to the use of a synchronous micro-forging process in Example 1, which refines the grain size, reduces microcrack sources, and improves the material's fatigue resistance. Furthermore, the cryogenic protective atmosphere and high vacuum processing environment reduce oxides and other defects within the material, further improving the material's fatigue performance.

[0176] As can be seen from Table 9, the crack growth rates of Examples 1-5 are significantly lower than those of Comparative Examples 1-3. The crack growth rate at 650°C in Example 1 is approximately 30% lower than that in Comparative Example 1. This is because Example 1 utilizes a synchronous micro-forging process and a dual-channel powder feeding system for gradient deposition, which optimizes the material's microstructure, improves its fracture toughness, and reduces the crack growth rate.

[0177] As can be seen from Table 10, the thermal fatigue life of Examples 1-5 is significantly longer than that of Comparative Examples 1-3. The thermal fatigue life of Example 1 is approximately 63% longer than that of Comparative Example 1. This is because Example 1 utilizes a synchronous micro-forging process and a dual-channel powder feeding system for gradient-ratio deposition, which optimizes the material's microstructure and improves its thermal fatigue resistance. Furthermore, the low-temperature protective atmosphere and high-vacuum processing environment reduce oxides and other defects within the material, further enhancing its thermal fatigue performance. Turbine disks are frequently subjected to thermal cycling loads during operation, and improving thermal fatigue life is crucial for their service life and safety.

[0178] As can be seen from Table 11, the oxidation resistance of Examples 1-5 is significantly superior to that of Comparative Examples 1-3, particularly Comparative Example 3. The 900°C / 100h oxidation weight gain of Example 1 is approximately 28% lower than that of Comparative Example 1 and approximately 63% lower than that of Comparative Example 3. This is because Example 1 utilizes a low-temperature protective atmosphere and a high-vacuum processing environment, which reduces initial oxides within the material and improves the material's oxidation resistance. This fully demonstrates that the low-temperature protective atmosphere and high-vacuum processing environment employed in the present invention can effectively reduce initial oxides within the material and improve the material's oxidation resistance. Comparative Example 3, due to the lack of a low-temperature protective atmosphere and a high-vacuum processing environment, exhibits a higher initial degree of oxidation within the material, significantly reducing its oxidation resistance.

[0179] As can be seen from Table 12, the thermal stability of Examples 1-5 is significantly better than that of Comparative Examples 1-3. The hardness of Example 1 decreases by about 5% after 900°C / 500h heat exposure, while that of Comparative Example 1 decreases by about 9%, and that of Comparative Example 3 decreases by about 12%, which shows that Example 1 has better thermal stability. This is because Example 1 uses a synchronous micro-forging process and a dual-channel powder feeding system to perform gradient ratio deposition, which optimizes the microstructure of the material, especially the size, morphology and distribution of the γ' phase, and improves the thermal stability of the material. At the same time, the low-temperature protective atmosphere and high-vacuum treatment environment reduce oxides and other defects inside the material, further improving the thermal stability of the material. This fully proves that the process adopted by the present invention can effectively improve the thermal stability of the material. The turbine disc is prone to microstructural evolution under long-term high-temperature working environment. The improvement of thermal stability is of great significance for maintaining the long-term performance of the turbine disc.

[0180] In summary, Examples 1-5 show significant advantages over Comparative Examples 1-3 in terms of microstructure, mechanical properties, and high-temperature performance. Specifically, compared with Comparative Example 1, Example 1 has room temperature and high-temperature tensile strengths increased by 12% and 14% respectively, endurance life increased by 78% and 80%, fatigue life increased by 67% and 80%, crack growth rate decreased by 30%, thermal fatigue life increased by 63%, oxidation weight gain decreased by 28%, and thermal stability increased by 4 percentage points. Compared with Comparative Example 2, Example 1 has endurance life increased by 33% and 50%, fatigue life increased by 39% and 50%, crack growth rate decreased by 22%, thermal fatigue life increased by 42%, oxidation weight gain decreased by 22%, and thermal stability increased by 3 percentage points. Compared with Comparative Example 3, Example 1 has room temperature and high-temperature tensile strengths increased by 10% and 19% respectively, endurance life increased by 100% and 112%, fatigue life increased by 92% and 125%, crack growth rate decreased by 36%, thermal fatigue life increased by 77%, oxidation weight gain decreased by 63%, and thermal stability increased by 7 percentage points.

[0181] These results fully demonstrate that the innovative process combination of the present invention, including the dual-channel powder feeding system and cryogenic protective atmosphere in the arc powder feeding additive process, timely forging and appropriate forging parameters in the synchronous micro-forging process, and subsequent hot isostatic pressing, homogenization, and solution and aging treatments, can effectively improve the microstructure and overall performance of high-temperature alloy turbine disks, especially their high-temperature performance. This is of great significance for improving the reliability, safety, and service life of aircraft engine turbine disks, as well as reducing their weight and improving the engine's thrust-to-weight ratio.

[0182] Although the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the scope of the patent coverage of the present invention.

Claims

1. The application of dual-channel powder feeding process in the preparation of aircraft engine turbine disk blanks is characterized by: The high-temperature alloy powder is deposited in a gradient ratio through a dual-channel system through an arc powder feeding additive process, forming a material gradient distribution in the center, transition and edge areas of the disk. At the same time, a synchronous micro-forging process is used to apply dynamic mechanical deformation to the new deposited layer in a high-temperature plastic state. The obtained turbine disk blank is subjected to hot isostatic pressing treatment, high-temperature homogenization annealing is carried out in a vacuum furnace, and finally, the turbine disk blank is obtained through solid solution treatment and aging treatment.

2. The use according to claim 1, characterized in that The following steps are involved: Arc powder feeding additive process: High-temperature alloy powder is deposited in a gradient ratio through a dual-channel powder feeding system. This includes adding material to the disk center, transition zone, and rim. Gradient material distribution is achieved by adjusting the powder feeding rates of the two powder feeding channels. The general parameters of the arc powder feeding additive process include powder feeding speed of the mixing powder channel, arc current, arc voltage, deposition layer thickness, interlayer residence time and protective atmosphere; S2. Synchronous micro-forging process: Mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state while the material is being accumulated. Dynamic extrusion or rolling is applied to the newly deposited layer through a micro-rolling forging mechanism. S3. Hot Isostatic Pressing (HIPPING) heat treatment process: Hot isostatic pressing (HIPPING) is performed on the turbine disk blank after additive manufacturing and simultaneous micro-forging. S4. Homogenization: The hot isostatically pressed blank is subjected to high-temperature homogenization annealing in a vacuum furnace; S5. Solution + aging heat treatment process: The homogenized blank is subjected to solution treatment and aging treatment in a vacuum furnace to obtain a turbine disk blank.

3. The use according to claim 2, characterized in that In S1, the gradient ratio of the additive in the center area of ​​the disk is as follows: the powder feeding rate of channel 1 is set to 2.5-4.0 m / min, and the powder feeding rate of channel 2 is set to 0.5-1.5 m / min or 0 m / min; The gradient ratio of the additive in the transition zone is as follows: as the additive path moves from the center of the disk to the edge of the disk, the powder feeding rate of channel 1 gradually decreases, while the powder feeding rate of channel 2 gradually increases; The gradient ratio of the additive in the disk edge area is: set the powder feeding rate of channel one to 0.5-1.5m / min or 0m / min, and set the powder feeding rate of channel two to 2.5-4.0m / min.

4. The use according to claim 2, characterized in that In S1, the general parameters of the arc powder feeding additive process are specifically: Mixed powder channel powder feeding speed: 1~5m / min; Arc current: 100~300A; Arc voltage: 15~25V; Sediment layer thickness: 0.5~2mm; Interlayer residence time: 10~30s; Protective atmosphere: high-purity Ar gas, flow rate 10-25L / min, temperature controlled at -15~0℃.

5. The use according to claim 2, characterized in that In S2, the parameters for applying mechanical deformation are: Forging timing: immediately after each layer or layers of material solidify and are at a high temperature of 800-1150℃; Forging method: applying unidirectional or multidirectional dynamic extrusion or rolling to the newly deposited layer through a micro-rolling forging mechanism; Forging pressure: 50~200MPa; Forging mechanism moving speed: 1~5m / min; Reduction rate: 5%~20%.

6. The use according to claim 2, characterized in that In S3, the parameters of the hot isostatic pressing treatment are: Pressure: 100~150MPa; Temperature: 1000~1200℃; Keep warm time: 2~4 hours; Heating and cooling rate: 3-10℃ / min.

7. The use according to claim 2, characterized in that In S4, the parameters of the high temperature homogenization annealing are: Processing environment: vacuum degree is better than 5×10⁻²Pa, and it is recommended to reach 1×10⁻³Pa or higher; Temperature: 900~1110℃; Keep warm time: 1~3 hours; Cooling method: furnace cooling or controlled rate cooling.

8. The use according to claim 2, characterized in that In S4, the parameters of the solution treatment are: temperature 800-1000° C., holding time 2-4 hours, and cooling method of oil quenching, gas quenching or water quenching.

9. The use according to claim 2, characterized in that In S4, the parameters of the aging treatment are: temperature 600~700℃, holding time 8~16 hours, and cooling method is air cooling or furnace cooling.

10. The use according to claim 2, characterized in that The specific steps include: S1. Arc powder feeding additive process: High-temperature alloy powder is deposited in a gradient ratio through a dual-channel powder feeding system. Specifically: Additive manufacturing in the center of the disk: Set the powder feeding rate of channel 1 to 2.5-4.0 m / min, and the powder feeding rate of channel 2 to 0.5-1.5 m / min or 0 m / min; Additive in the transition zone: As the additive path moves from the center of the disk to the edge, the powder feeding rate of channel 1 gradually decreases, while the powder feeding rate of channel 2 gradually increases; Additive manufacturing in the disk edge area: Set the powder feeding rate of channel 1 to 0.5-1.5m / min or 0m / min, and set the powder feeding rate of channel 2 to 2.5-4.0m / min; The general parameters of the arc powder feeding additive process are: Mixed powder channel powder feeding speed: 1~5m / min; Arc current: 100~300A; Arc voltage: 15~25V; Sediment layer thickness: 0.5~2mm; Interlayer residence time: 10~30s; Protective atmosphere: high-purity Ar gas, flow rate 10-25L / min, temperature controlled at -15~0℃; S2. Synchronous micro-forging process: Mechanical deformation is applied to the newly deposited material layer in a high-temperature plastic state while the material is being accumulated. Specifically: Forging timing: immediately after each layer or layers of material solidify and are at a high temperature of 800-1150℃; Forging method: applying unidirectional or multidirectional dynamic extrusion or rolling to the newly deposited layer through a micro-rolling forging mechanism; Forging pressure: 50~200MPa; Forging mechanism moving speed: 1~5m / min; Reduction rate: 5% to 20%; S3. Hot isostatic pressing heat treatment process: The turbine disk blank that has completed additive manufacturing and simultaneous micro-forging is subjected to hot isostatic pressing treatment. The specific parameters are: Pressure: 100~150MPa; Temperature: 1000~1200℃; Keep warm time: 2~4 hours; Heating and cooling rate: 3-10℃ / min; S4. Homogenization treatment: The hot isostatic pressed blank is subjected to high temperature homogenization annealing in a vacuum furnace. The specific parameters are: Processing environment: vacuum degree is better than 5×10⁻²Pa, and it is recommended to reach 1×10⁻³Pa or higher; Temperature: 900~1110℃; Keep warm time: 1~3 hours; Cooling method: furnace cooling or controlled rate cooling; S5. Solution + Aging Heat Treatment Process: In a vacuum furnace with a vacuum degree of ≤1×10⁻³Pa, the homogenized blank is subjected to standard solution treatment and aging treatment to obtain a turbine disk blank. Specifically: Solution treatment: temperature 800~1000℃, holding time 2~4 hours, cooling method adopts oil quenching, gas quenching or water quenching; Aging treatment: temperature 600~700℃, holding time 8~16 hours, cooling method adopts air cooling or furnace cooling.

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