Ni-Based Superalloy Ring Nosing for Defect-Free Tapering
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Solution Overview
Problem
The nosing process for manufacturing tapered materials from Ni-based superalloys often results in molding defects, such as bending and deformation towards the outer circumference, due to the high high-temperature strength and difficulty in plastic working of these alloys.
Innovation Solution
A method for manufacturing tapered materials that involves subjecting a ring material made of Ni-based superalloy to a nosing process, where the nosing process initial temperature of another portion of the circumferential surface not subjected to the process is set within a specific range (Ts-300≤Tn≤Ts-50) relative to the solvus temperature of the alloy, to prevent material deformation and molding defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If nosing process is applied to ring material made of Ni-based superalloy, then tapered shape can be imparted, but molding defects such as bending and deformation occur in the cylindrical section
Solution Approach 1:
The invention changes the temperature parameter of the ring material during nosing process. By heating the ring material to a specific temperature range (above room temperature but below melting point), the material becomes more ductile and easier to deform, allowing the tapered shape to be imparted without causing bending or deformation defects in the cylindrical section.
Solution Approach 2:
The invention applies preliminary heating to the ring material before performing the nosing process. This preliminary thermal treatment prepares the material by increasing its plasticity, so that when the nosing die applies force to create the tapered shape, the material can deform uniformly without developing molding defects.
2Productivity
If nosing process is used on Ni-based superalloy, then working time is reduced, but material cracking occurs due to high high-temperature strength
Solution Approach 1:
The invention changes the temperature parameter to resolve the contradiction between productivity and reliability. By performing nosing process at elevated temperature, the Ni-based superalloy's high-temperature strength is reduced, making the material more ductile and resistant to cracking, while still maintaining relatively efficient processing speed.
Solution Approach 2:
The invention makes the material properties dynamic by utilizing temperature-dependent behavior of Ni-based superalloy. The material is heated to change its mechanical properties temporarily during processing, allowing easier deformation without cracking, then cooled to regain its high-strength properties in the final product.
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 imparts a tapered shape without molding defects, enhancing deformation resistance and preventing material cracking, thereby ensuring the production of high-quality tapered materials from expensive Ni-based superalloys.
Implementation Method 1
a solvus temperature Ts (° C.) of a precipitation phase of the Ni-based superalloy
Data Source
AI summary
To provide a method for manufacturing a tapered material, which can impart a tapered shape without any molding defect when a ring material made of Ni-based superalloy is subjected to a nosing process. In a nosing process to obtain a tapered material 10 by covering and pressing an entire circumference of an end portion of a ring material 10R made of Ni-based superalloy with a tapered portion 32 of an inner surface of a nosing die 30 to deform a portion of the circumferential surface of the ring material 10R into a tapered shape along the tapered inner surface portion 32 of the die 30, a nosing process initial temperature Tn (° C.) of another portion 13 of the circumferential surface of the ring material 10R where the nosing process is not applied satisfies a relationship of following Formula 1 with a solvus temperature Ts (° C.) of a precipitation phase of the Ni-based superalloy:Ts-300≤Tn≤Ts-50.(Formula 1)