DESIGN OF FORGING METHODS OF HEALING DEFECTS IN INGOTS EFFECTIVELY

doi:10.11900/0412.1961.2016.00393

Acta Metall Sin

2016, Vol. 52

Issue (10): 1199-1206 DOI: 10.11900/0412.1961.2016.00393

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DESIGN OF FORGING METHODS OF HEALING DEFECTS IN INGOTS EFFECTIVELY

Dianzhong LI¹,Xuan MA^1,^2,³,Bin XU^1,⁴(

),Mingyue SUN^1,⁴

1 Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
2 College of Physical Science and Technology, Shenyang Normal University, Shenyang 110034, China
3 School of Materials Science and Engineering, Dalian University of Technology, Dalian 116085, China
4 Key Laboratory of Nuclear Materials and Safety Assessment, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

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Dianzhong LI, Xuan MA, Bin XU, Mingyue SUN. DESIGN OF FORGING METHODS OF HEALING DEFECTS IN INGOTS EFFECTIVELY. Acta Metall Sin, 2016, 52(10): 1199-1206.

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Abstract

Large forgings are the fundamental parts of many kinds of key equipment, and large ingots are the basis of large forgings. There are severe metallurgical defects in large ingots, such as porosities, shrinkage cavities and gas cavities. The continuity of material is damaged by the defects, which must be eliminated during forging process. Using FEM simulation, it is found that void shape is the most important parameter affecting void closing during hot forging. Height-diameter ratio of the void is defined to describe the effect of void shape. The simulation results show that the larger height-diameter ratio of the void, the harder it is for the void to close. Based on these results, wide anvil radial forging (WRF) method is proposed. WRF method can concentrate the strain on the center of the ingot; make the height-diameter ratio of the voids smallest and heal shrinkage cavities effectively. Another one direction heavy forging method is proposed to be used on smaller forging machines. Using this method, the billet is forged along the same direction for two passes. This method can heal defects effectively with small pressure. Based on interface healing rules, temperature dwelling forging method for forging tube plates are proposed. A tube plate with defects is repaired using this method. These forging methods have been used on industrial experiments, and have been proved to be able to heal the defects in the billets and increase qualified rate of the forgings.

Key words: void closure wide anvil radial forging one direction heavy forging temperature dwelling forging

Received: 02 September 2016

ZTFLH:

Fund: Supported by National Natural Science Foundation of China (No.U1508215), National Key Research and Development Program of China (No.2016YFB0300401) and Liaoning BaiQianWan Talents Program (No.【2015】 12)

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https://www.ams.org.cn/EN/10.11900/0412.1961.2016.00393 OR https://www.ams.org.cn/EN/Y2016/V52/I10/1199

Fig.1 Effect of void shape on critical height reduction ratio^[10]

Fig.2 Void shapes and strain distribution of samples with an ellipse void under different reduction ratios^[28]
(a) original shape (void height-diameter ratio h/d=3)
(b) reduction ratio of 20%
(c) reduction ratio of 32.5%
(d) void closed under reduction ratio of 41.5%

Fig.3 Simulation of void crushing using wide anvil radial forging^[10]
(a) strain distribution after wide anvil radial forging
(b) void shape after wide anvil radial forging

Fig.4 Picture of the continuous casting billet^[10]
(a) section of the continuous casting billet
(b) local amplification of the center of the billet

Fig.5 Forging processes of the continuous casting billet^[28]
(a) heating before forging (b) wide-anvil radial forging (c) cogging (d) rounding to final dimension

Fig.6 Macrostructure of forged continuous casting billet using wide anvil radial forging method^[28]
(a) cross section of the billet (b) local amplification of the center of billet

Fig.7 Macrostructures of defects in the center of the long casting ingot

Fig.8 Photo of long casting ingot after two forging passes along the same direction

Fig.9 Tube plates (a) and sketch of defect area (unit: mm) (b)^[28]

Fig.10 Die positioning during forging of the tube plate and its defect area^[28]

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[1]	XU Bin SUN Mingyue LI Dianzhong. THE VOID CLOSE BEHAVIOR OF LARGE INGOTS DURING HOT FORGING[J]. 金属学报, 2012, 48(10): 1194-1200.

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