Alloy Ingot Surface Layering to Prevent Hot-Working Cracks
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Solution Overview
Problem
Alloy ingots, particularly crack-sensitive alloys like nickel base, iron base, and cobalt base alloys, experience surface cracking during hot working operations due to thermal gradients, leading to low production yields.
Innovation Solution
A metallic material layer is deposited onto the surface of the alloy ingot, which is more ductile and tougher than the underlying alloy, to insulate the ingot from die surfaces and prevent cooling to brittle temperatures, thereby reducing surface cracking during hot working.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If alloy ingots undergo hot working operations, then alloy products can be produced, but surface cracking occurs due to thermal gradients
Solution Approach 1:
A deposited metallic material layer acts as an intermediary between the die surface and the alloy ingot. This intermediate layer insulates the ingot from the die, preventing rapid cooling that causes surface cracking during hot working operations, thereby maintaining both productivity and reliability
2Ease of manufacture
If thermal gradients are present during hot working, then alloy products can be formed, but surface cracking is induced
Solution Approach 1:
The metallic material layer is deposited on the alloy ingot surface before hot working operations. This pre-applied layer cushions the ingot against thermal shocks and rapid cooling from die contact, preventing surface cracking while allowing the hot working process to proceed
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
The deposited metallic material layer significantly reduces the incidence of surface cracking, allowing for more effective hot working of alloy ingots with improved yield and quality of the final products.
Implementation Method 1
A metallic material layer is deposited onto the surface of the alloy ingot, which is more ductile and tougher than the underlying alloy, to insulate the ingot from die surfaces and prevent cooling to brittle temperatures
Data Source
AI summary
Processes and methods related to processing and hot working alloy ingots are disclosed. A metallic material layer is deposited onto at least a region of a surface of an alloy ingot before hot working the alloy ingot. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.