Heat-Retaining Coating for Alloy Ingot Hot Forging
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Solution Overview
Problem
High-deformation resistance alloys, such as age-hardening and Ni-based alloys, face challenges during hot forging due to temperature fluctuations, leading to cracks and inefficient processing, as existing heat-retaining methods fail to maintain consistent temperature and adhere well to the alloy ingots.
Innovation Solution
A method involving suspending a round-rod alloy ingot in a columnar mold, applying a heat-retaining metal coating around it, and performing hot forging while gripping the coated end portion to minimize temperature decrease, allowing continuous one-directional forging with fewer process steps and improved heat retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a heat-retaining sheet is simply wound around the alloy ingot, then the structure is simple, but the followability during deformation is insufficient causing gaps and unstable heat retention
Solution Approach 1:
The patent uses a flexible heat-retaining sheet made of heat-resistant ceramic fibrous material that can conform to the deforming alloy ingot. The sheet's flexibility allows it to maintain close contact during forging deformation, preventing gaps while retaining heat effectively throughout the process.
2Temperature
If the alloy ingot is heated to high temperature for forging, then the deformation resistance decreases, but the temperature decreases rapidly during processing reducing effective working time
Solution Approach 1:
The heat-retaining sheet is applied to the alloy ingot before the forging process begins. This pre-application creates a thermal insulation barrier that cushions against heat loss during deformation, allowing the ingot to maintain forging temperature throughout the entire processing sequence without rapid cooling.
Solution Approach 2:
The heat-retaining sheet acts as an intermediary between the alloy ingot and the surrounding environment. It mediates heat transfer by providing thermal insulation, preventing direct heat loss to the atmosphere while allowing the forging process to proceed at elevated temperatures for extended periods.
3Ease of manufacture
If the heat-retaining sheet is made to easily become damaged for easy removal, then the removal is simple, but it drops down during forging interfering with the finishing surface
Solution Approach 1:
The patent uses a foam model that replicates the shape of the alloy ingot to position and secure the heat-retaining sheet. The foam model serves as a temporary support structure that holds the sheet in place during forging, preventing it from dropping onto the finishing surface while allowing easy removal after processing.
4Temperature
If multiple reheating cycles are performed to complete forging, then the temperature is maintained, but the processing efficiency decreases
Solution Approach 1:
The heat-retaining sheet enables continuous forging operations by maintaining temperature throughout the entire deformation process. This eliminates the need to stop and reheat between forging passes, allowing the useful action of deformation to continue uninterrupted and significantly improving processing efficiency.
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 method effectively maintains the alloy ingot at a predetermined temperature for a longer period, reducing temperature gradients and deformation resistance, enabling stable and efficient hot forging of high-performance alloys with fewer heating cycles and reduced risk of coating damage.
Implementation Method 1
applying a heat-retaining metal coating around it, and performing hot forging while gripping the coated end portion to minimize temperature decrease
Data Source
AI summary
The present invention relates to a method for manufacturing a round-rod shaped alloy ingot by hot forging, containing suspending a primary alloy ingot having a round-rod shape in a columnar mold while one end of the primary alloy ingot is held, pouring a molten metal formed of a heat-retaining metal into the columnar mold so as to apply a coating of the heat-retaining metal to the entire circumference of the primary alloy ingot, to obtain a forging alloy ingot, taking the forging alloy ingot out from the columnar mold, then subjecting the forging alloy ingot to a hot forging while an end portion of the forging alloy ingot is gripped as a gripping portion, and removing the coating of the heat-retaining metal.