Niobium-Tungsten Forged Ring Processing for Large-Diameter Crack Control
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Solution Overview
Problem
The manufacturing of niobium-tungsten alloy forged parts is limited by high cost, poor high-temperature plasticity, narrow forging temperature range, large deformation resistance, and difficulty in producing parts with diameters greater than 350 mm due to cracking and low material utilization rates.
Innovation Solution
A method involving blanking, turning, and chamfering of niobium-tungsten alloy ingots, followed by spraying an anti-oxidation coating, sheathing with stainless-steel, heating, and upsetting to form a primary pancake, then machining and vacuum stress-relief annealing to create a ring blank, which is further forged using core shaft/saddle techniques and vacuum recrystallization annealing to produce a desired forged ring with enhanced tensile strength and material utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional machining methods are used to produce niobium-tungsten alloy forged parts, then the parts can be manufactured, but the material utilization rate is low and the cost is high
Solution Approach 1:
The patent changes the manufacturing approach from traditional machining to forging process, transforming the material forming method. By using forging with specific temperature control and deformation parameters, the material is shaped directly into the final form with minimal waste, achieving high material utilization rate while reducing manufacturing cost
Solution Approach 2:
The patent replaces the traditional mechanical machining system with a thermomechanical forging system. Instead of removing material through cutting tools, the material is plasticized through heating and then formed through mechanical deformation, fundamentally changing the manufacturing paradigm to achieve better material efficiency
2Strength
If the niobium-tungsten alloy is deformed through repeated upsetting and stretching, then the deformation can be enhanced, but the alloy is easy to crack during the stretching process
Solution Approach 1:
The patent applies parameter changes by controlling the temperature within the specific range of 1000-1300°C during forging, and by controlling the deformation amount in each step. This prevents the material from becoming too brittle while achieving the required deformation, avoiding cracking that would occur at lower temperatures or with excessive single-step deformation
Solution Approach 2:
The patent performs preliminary heating to plasticize the material before deformation. By pre-heating the alloy to the appropriate temperature range before applying mechanical deformation, the material gains sufficient plasticity to undergo the required shaping without cracking, enabling subsequent deformation steps to proceed reliably
3Manufacturing precision
If a forged bar or disk is used to machine a thrust chamber body with diameter equal to or larger than 350 mm, then the part can be produced, but the material utilization rate is low and the cost is high
Solution Approach 1:
The patent segments the forging process into multiple controlled steps including heating, deformation, and heat treatment. By dividing the manufacturing process into discrete stages with intermediate inspections and adjustments, the method achieves precise dimensional control for large-diameter parts while optimizing material usage through progressive forming
Solution Approach 2:
The patent employs parameter changes by controlling the forging temperature within 1000-1300°C and adjusting deformation parameters according to the specific stage of processing. This enables precise control over the material flow and final dimensions, achieving both high dimensional accuracy and material efficiency for large-scale components
4Force
If the niobium-tungsten alloy is forged at high temperature, then the deformation resistance is reduced, but the forging temperature range is narrow
Solution Approach 1:
The patent applies parameter changes by identifying and controlling the specific temperature range of 1000-1300°C where the alloy exhibits optimal plasticity. Within this narrowed window, the material achieves sufficient softness for deformation while maintaining structural integrity, resolving the contradiction between needing high temperature for low deformation resistance and the material's limited temperature tolerance
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 method achieves a tensile strength of 400 MPa at room temperature, 140 MPa at 1400°C, and 90 MPa at 1600°C, enabling the production of niobium-tungsten alloy forged rings with diameters greater than 350 mm, improving material utilization and reducing deformation resistance and cracking issues.
Implementation Method 1
spraying an anti-oxidation coating on a surface of the primary blank to obtain a secondary blank
Implementation Method 2
sheathing the secondary blank with a stainless-steel sheath followed by heating to obtain a tertiary blank
Implementation Method 3
subjecting the primary pancake to vacuum stress-relief annealing to obtain a secondary pancake
Implementation Method 4
subjecting the crude forged ring to vacuum recrystallization annealing to obtain a desired forged ring
Data Source
AI summary
A method for forging a niobium-tungsten alloy forged ring, including: (S1) subjecting an alloy ingot to turning, chamfering, spraying with an anti-oxidation coating, stainless-steel sheathing, heating and upsetting to obtain a primary pancake with a flat-die hammer, rapid-forging press or hydraulic press; (S2) subjecting an inner pole to wire electrical discharge machining to obtain a ring blank followed by machining to remove the stainless-steel sheath and oxide scale and defects; and subjecting the ring blank to fluorescent/dye penetrant inspection followed by vacuum stress-relief annealing; (S3) subjecting the ring blank to core shaft/saddle forging on the flat-die hammer or rapid-forging press to obtain a crude forged ring; and (S4) subjecting the crude forged ring to vacuum recrystallization annealing to obtain a desired forged ring.