Hot Forging Temperature Control to Prevent Double-Barreling
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Solution Overview
Problem
Hot die forging of materials with Ni-based super heat-resistant alloys at temperatures above 950°C often results in double-barreling shaped forging defects due to temperature variations during the transfer process, leading to reduced yield and increased manufacturing costs, as existing methods either require coating the material or shortening transfer times, both of which are inefficient.
Innovation Solution
A method involving heating the material and dies to specific temperature ranges (1025-1150°C and 950-1075°C respectively) with a temperature difference of 75°C or more, using Ni-based super heat-resistant alloys for the dies and applying a lubricating coating to prevent temperature loss during transfer, thereby maintaining consistent surface temperatures and preventing double-barreling defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the die temperature is increased to reduce temperature difference with the material, then the workability of the material improves and the shape near the final shape is achieved, but the die life decreases due to reduced high-temperature strength
Solution Approach 1:
The invention changes the material parameter of the die from conventional heat-resistant alloys to Ni-based super heat-resistant alloys with specific composition ranges (Cr: 5-20%, Co: 5-20%, W: 5-20%, Mo: 5-15%). This material parameter change enables the die to maintain high strength at elevated temperatures (950-1150°C), allowing the die temperature to be increased to reduce the temperature difference with the material while preserving die life.
2Manufacturing precision
If the transfer time is shortened to prevent temperature loss, then the temperature consistency is improved, but the equipment complexity increases and productivity decreases
Solution Approach 1:
The invention applies preliminary anti-action by pre-heating the die to a temperature close to the material temperature before the transfer process. This preliminary heating creates a thermal environment that minimizes temperature loss during transfer, eliminating the need for extremely short transfer times while maintaining temperature consistency.
Solution Approach 2:
The invention introduces a lubricating coating as an intermediary between the material and the die. This coating layer acts as a thermal buffer that reduces heat loss from the material surface during transfer, maintaining temperature consistency without requiring rapid transfer operations.
3Manufacturing precision
If a lubricating coating is applied to prevent temperature loss, then the temperature consistency is improved, but the device complexity and operation time increase
Solution Approach 1:
The invention employs a lubricating coating that can be applied as a thin, disposable layer on the die surface. This coating serves its primary function of reducing heat loss and facilitating transfer, then can be easily removed or allowed to wear off, avoiding the need for complex coating application and removal equipment while maintaining temperature consistency.
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
Prevents the generation of double-barreling shaped forging defects, improving the quality and yield of hot forged materials while maintaining productivity by ensuring consistent temperature conditions during the forging process.
Implementation Method 1
a first strength increasing element which forms a solid solution in a γ-phase and a second strength increasing element which forms a precipitate in the γ-phase
Implementation Method 2
a first strength increasing element which forms a solid solution in a γ-phase and a second strength increasing element which forms a precipitate in the γ-phase
Implementation Method 3
a raw material heating step of heating the material for hot forging in a furnace to a heating temperature within a range of 1025 to 1150° C.; a die heating step of heating the upper die and the lower die to a heating temperature within a range of 950 to 1075° C.
Data Source
AI summary
Provided is a method for producing a hot forged material capable of preventing the generation of double-barreling shaped forging defects. The method for producing a hot forged material, wherein both an upper die and a lower die are made of Ni-based super heat-resistant alloy and the method comprises a hot forging step of pressing a material for hot forging by the lower die and the upper die in the air to form the hot forged material, the method comprising: a raw material heating step of heating the material for hot forging in a furnace to a heating temperature within a range of 1025 to 1150° C.; a die heating step of heating the upper die and the lower die to a heating temperature within a range of 950 to 1075° C.; and a transferring step of transferring the material for hot forging onto the lower die by a manipulator after the completion of the raw material heating step and the die heating step, wherein a value obtained by subtracting the heating temperature of the upper die and the lower die from the heating temperature of the material for hot forging is 75° C. or more.