INTEGRATED SIMULATION OF THE FORGING PROCESS FOR GH4738 ALLOY TURBINE DISK AND ITS APPLICATION

doi:10.3724/SP.J.1037.2013.00675

Acta Metall Sin

2014, Vol. 50

Issue (7): 821-831 DOI: 10.3724/SP.J.1037.2013.00675

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INTEGRATED SIMULATION OF THE FORGING PROCESS FOR GH4738 ALLOY TURBINE DISK AND ITS APPLICATION

LI Linhan, DONG Jianxin, ZHANG Maicang, YAO Zhihao(

)

School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083

Cite this article:

LI Linhan, DONG Jianxin, ZHANG Maicang, YAO Zhihao. INTEGRATED SIMULATION OF THE FORGING PROCESS FOR GH4738 ALLOY TURBINE DISK AND ITS APPLICATION. Acta Metall Sin, 2014, 50(7): 821-831.

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Abstract

In order to control the grain size of forged turbine disk of wrought superalloy like GH4738 more effectively, constitutive equations and grain structure evolution models of GH4738 alloy are used in Deform 3D^TM for achieving integrated simulation of whole forging process of GH4738 alloy turbine disk (from preheating billet for upsetting to die forging). By using of integrated simulation, the variation of temperature, average grain size, etc., during the whole forging process has been explored, making it possible to control these parameters quantitatively. Comparing with traditional simple stage simulation, results of integrated simulation are more consistent with corresponding experimental results of forged turbine disk (300 mm in diameter). Therefore, the reliability of the integrated simulation is verified. Finally, with the application of integrated simulation, GH4738 alloy turbine disk with a diameter of 1450 mm has been successfully forged by 8×10⁴t forging press. This work provides a more practical simulation method for helping the process design of forging large turbine disk.

Key words: GH4738 alloy turbine disk integrated simulation

Received: 25 October 2013

ZTFLH:	TG132.32
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	Linhan LI
	Jianxin DONG
	Maicang ZHANG
	Zhihao YAO

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https://www.ams.org.cn/EN/10.3724/SP.J.1037.2013.00675 OR https://www.ams.org.cn/EN/Y2014/V50/I7/821

Fig.1 Optical microstructure of GH4738 alloy cogginged billet

Fig.2 Schematic of forging process of GH4738 alloy turbine disk

Fig.3 Flow chart of finite element module for computing GH4738 alloy microstructure evolution (ε—strain, ε_c—critical strain, Drx—dynamic recrystallization, X_Drx—fraction of Drx, Mdrx and Srx—meta-dynamic recrystallization and static recrystallization, X_Mdrx-Srx—fraction of Mdrx and Srx, d_Mdrx-Srx—average grain size after Mdrx and Srx)

Fig.4 Schematic of researched locations in the billet (diameter 100 mm, length 270 mm) (a) and the simulated results of temperature and grain size in these locations during the preheating stage of upsetting (b)

Fig.5 Variation of average grain size of samples (initial grain size is 165 μm) under heat treatments at 1060 ℃ and 1080 ℃ and corresponding OM images

Fig.6 Simulation results and test values of temperatures in P₁, P₂ and P₃of canned billet during transfer stage

Fig.7 Average grain size distributions of the workpiece before and after upsetting in traditional simple simulation (a) and integrated simulation (b)

Fig.8 Temperature distributions of the workpiece before and after upsetting in traditional simple simulation (a) and integrated simulation (b)

Fig.9 Average grain size distribution of upsetted billet after air cooling in integrated simulation

Fig.10 Schematic of researched locations in the upsetted billet (a) and the simulated results of temperature and grain size in these locations during the preheating stage of die forging in integrated simulation (b)

Fig.11 Simulation results and test values of temperature in P₁, P₂ and P₃ of canned billet during transfer stage after preheating for die forging

Fig.12 Forge cracks of the work piece transferred in 210 s

Fig.13 Simulated distributions of temperature for work piece before and after die forging by traditional simple simulation (a) and integrated simulation (b)

Fig.14 Simulated distribution of average grain size for workpiece before and after die forging by traditional simple simulation (a) and integrated simulation (b)

Fig.15 Distribution of average grain size of die forged work piece after air cooling in integrated simulation

Fig.16 Distribution of average grain size in the vertical section along the axis of the final work piece (300 mm in diameter) in integrated simulation (a) and real optical microstructures (b~f) of locations 1~5 shown in Fig.16a

Fig.17 Simulated distribution result of average grain size in the vertical section along the axis of the final work piece (300 mm in diameter) by traditional simple simulation

Fig.18 Changes of average grain size in locations 1~5 after eight stages (showing in Fig.2) in integrated simulation

Fig.19 Simulated results of final average grain size distribution of forged turbine disk (1450 mm in diameter) under one kind of process condition (a) and an optimized process condition (b)

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