Additive Preform Single-Die Forging for Titanium Aluminides
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Solution Overview
Problem
Current metal forging processes are inefficient in producing complex shapes with improved mechanical properties and require multiple dies, which increases costs and complexity, especially when dealing with low ductility materials like titanium aluminides.
Innovation Solution
The method involves using additive manufacturing to create a metal shaped-preform, which is then forged using a single die at a lower temperature than the preform, followed by optional annealing, to achieve desired strains and properties, such as improved surface hardness and reduced porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple dies are used for successive forging steps, then complex shapes can be achieved, but device complexity and manufacturing costs increase
Solution Approach 1:
A preform with an intermediate shape is created before the final forging operation. This preform is designed to require only a single die for the final shaping operation, eliminating the need for multiple successive dies while still achieving the desired complex final shape
Solution Approach 2:
The forging process is segmented into two distinct stages: (1) additive manufacturing of a preform with intermediate geometry, and (2) single-die forging to final shape. This segmentation allows each stage to be optimized independently, reducing overall process complexity
2Ease of manufacture
If isothermal forging is used for low ductility materials, then forging can be performed, but process complexity and energy consumption increase
Solution Approach 1:
The material's ductility is improved through additive manufacturing parameters (layer-by-layer construction, controlled cooling rates) rather than through thermal softening during forging. This allows conventional single-die forging at lower temperatures without requiring isothermal conditions
Solution Approach 2:
The additive manufacturing process replaces the thermal-mechanical preheating and isothermal holding steps of traditional forging. The layer-by-layer deposition inherently creates a more ductile microstructure, eliminating the need for complex thermal management during forging
3Reliability
If conventional forging is used on as-built additive parts, then porosity and surface roughness are high, but additional processing steps are required
Solution Approach 1:
The preform is additively manufactured with optimized parameters (layer orientation, infill density, cooling rates) to minimize porosity and surface roughness before forging. This preliminary optimization reduces the severity of defects that would otherwise require additional processing steps to correct
Solution Approach 2:
Different regions of the preform are manufactured with locally optimized parameters. Critical areas that will undergo high strain during forging are manufactured with different layer orientations and densities than non-critical areas, optimizing the balance between defect reduction and forging performance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the production of forged metal products with enhanced mechanical properties and reduced manufacturing costs, particularly effective for low ductility materials like titanium aluminides, by eliminating the need for multiple dies and isothermal forging.
Implementation Method 1
additive manufacturing to produce a metal shaped-preform
Implementation Method 2
contacting the metal shaped-preform with a forging die... deforming the metal shaped-preform via the forging die to realize a true strain
Implementation Method 3
heating the metal shaped-preform to a stock temperature
Implementation Method 4
annealing the final forged product... heating the final forged product to a temperature of from about 640° C. to about 816° C.
Data Source
AI summary
Methods for producing forged products and other worked products are disclosed. In one embodiment, a method comprises using additive manufacturing to produce a metal shaped-preform and, after the using step, forging the metal shaped-preform into a final forged product. The final forged product may optionally be annealed.