U.S. patent application number 11/118509 was filed with the patent office on 2005-09-15 for method of joining material.
This patent application is currently assigned to UNITED TECHNOLOGIES CORPORATION. Invention is credited to DeMichael, Thomas, Robertson, John M., Walker, Raymond M..
Application Number | 20050199683 11/118509 |
Document ID | / |
Family ID | 22121368 |
Filed Date | 2005-09-15 |
United States Patent
Application |
20050199683 |
Kind Code |
A1 |
Robertson, John M. ; et
al. |
September 15, 2005 |
Method of joining material
Abstract
A method of repairing a part, such as a rotating disk/drum rotor
of a gas turbine engine. The method includes: heating a contact
area of a wrought material and a contact area of a wrought part;
and pressing the contact area of the material against the contact
area of the part to bond the parts. A method of making a rotating
part of a gas turbine engine, comprising: heating a contact area of
a wrought material and a contact area of a wrought part; and
pressing the contact area of the material against the contact area
of the part to bond the parts. The methods may include a subsequent
heat treatment to provide the desired strength properties to the
joint between the material and the part.
Inventors: |
Robertson, John M.;
(Andover, CT) ; DeMichael, Thomas; (Stafford
Springs, CT) ; Walker, Raymond M.; (Lucie,
FL) |
Correspondence
Address: |
BACHMAN & LAPOINTE, P.C. (P&W)
900 CHAPEL STREET
SUITE 1201
NEW HAVEN
CT
06510-2802
US
|
Assignee: |
UNITED TECHNOLOGIES
CORPORATION
|
Family ID: |
22121368 |
Appl. No.: |
11/118509 |
Filed: |
April 28, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11118509 |
Apr 28, 2005 |
|
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|
10074736 |
Oct 29, 2001 |
|
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6902096 |
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Current U.S.
Class: |
228/119 |
Current CPC
Class: |
B23P 6/005 20130101;
B23K 20/02 20130101; F05D 2230/25 20130101; F05D 2230/23 20130101;
F05D 2230/40 20130101; F05D 2230/80 20130101; F01D 5/005 20130101;
B23K 2101/001 20180801 |
Class at
Publication: |
228/119 |
International
Class: |
B23K 020/12; B23K
031/02 |
Claims
1-7. (canceled)
8. A method of making a rotating part of a gas turbine engine,
comprising the steps of: providing a rotating part made from a
wrought material and having a contact area; providing a piece of
high strength wrought material having a contact area; resistance
heating said contact area of said material and said contact area of
said part; and pressing said contact area of said material against
said contact area of said part; wherein said material bonds to said
part.
9. The method as recited in claim 8, wherein the heating and
pressing steps comprise forge joining.
10. The method as recited in claim 8, wherein said part has an
anomaly thereon and the method further comprises the step of
treating said anomaly to form said contact area of said part.
11. The method as recited in claim 10, wherein the treating step
comprises machining said anomaly.
12. The method as recited in claim 8, wherein said part is not
fusion weldable.
13. The method as recited in claim 12, wherein said part is a
nickel-based superalloy or a titanium alloy.
14. The method as recited in claim 13, wherein said piece is made
from the same material as said part.
15. A method of repairing a rotating disk or drum rotor of a gas
turbine engine, comprising the steps of: providing a rotating disk
or drum rotor made from a wrought material and having an
arrangement of lugs and slots, at least one of said lugs or said
slots having an anomaly thereon; treating said anomaly to form a
contact area; providing a piece of high strength wrought material
having a contact area; directly heating said contact area of said
material and said contact area of said component; pressing said
contact area of said material against said contact area of said
component so that said material bonds to said component; and
treating said material to provide a desired shape to said disk or
drum.
16. The method as recited in claim 15, wherein the heating and
pressing steps comprise forge joining.
17. The method as recited in claim 15, wherein the treating steps
comprise machining.
18. The method as recited in claim 15, wherein said disk or drum is
not fusion weldable.
19. The method as recited in claim 18, wherein said disk or drum is
a nickel-based superalloy or a titanium alloy.
20. The method as recited in claim 19, wherein said piece is made
from the same material as said disk or drum.
21. The method as recited in claim 1, wherein said heating step
comprises resistance heating.
22. The method as recited in claim 21, wherein said heating step
includes applying an electric current across said contact
areas.
23. The method as recited in claim 8, wherein said heating step
includes applying an electric current across said contact
areas.
24. A method of repairing a part of a gas turbine engine comprising
the steps of: providing a part made from a wrought material and
having a contact area; providing a fixture having a base and a
replacement section formed from a high strength wrought material,
said replacement section having a contact area; heating said
contact area of said replacement section and said contact area of
said part by applying an electrical current to said replacement
section and said part; applying pressure to said fixture to move
said fixture towards said part until said contact area of said
replacement section comes into contact with said contact area of
said part and to allow said electrical current to travel across a
joint between said contact areas; and maintaining application of
said electrical current and said pressure until the wrought
material forming said replacement section has bonded to the wrought
material of said part.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation application of U.S.
patent application Ser. No. 10/074,736, filed Oct. 29, 2001,
entitled METHOD OF JOINING MATERIAL, by John M. Robertson et
al.
TECHNICAL FIELD
[0002] This invention relates to a method of joining material. More
particularly, this invention relates to a repair/rework method that
forge joins additional material to a part.
BACKGROUND OF THE INVENTION
[0003] The major components of a gas turbine engine include
(beginning at the upstream end, or inlet) a fan section, one or
more compressor sections, a burner section, one or more turbine
sections, and a nozzle. The engine may also include an
afterburner.
[0004] Air enters the engine through the inlet, travels past the
fan section, becomes compressed by the compressor sections, mixes
with fuel, and combusts in the burner section. The gases from the
burner section drive the turbine sections, then exit the engine
through the nozzle. If present, the afterburner could augment the
thrust of the engine by igniting additional fuel downstream of the
burner section.
[0005] The conditions (e.g. temperature and stress) at which
certain sections of an engine operate demand the use of high
temperature and high strength materials. Such materials include
nickel-based superalloys and titanium alloys. The cost of
manufacturing parts made from these materials can be quite high.
For example, certain engine parts made from these high temperature,
high strength materials could have a value of approximately
$200,000.
[0006] Errors can occur during the assembly or maintenance of the
engine. Damage to parts can occur during the assembly, maintenance
or operation of the engine. Such errors or damage create anomalies
on the part that may render the part unsuitable for use. Due to the
relatively high manufacturing costs of these parts, scrapping an
unsuitable part is not preferred. Scrapping the unsuitable part
should be used as a last resort since the engine part could have a
value of over $200,000.
[0007] Rather, the preferred solution is to repair or to rework the
unsuitable part. The repair/rework should remove the anomaly so as
to render the part suitable for use. This obviously assumes that
the part has suitable characteristics to withstand such repair or
rework. However, current repair or rework techniques are not
compatible with the aforementioned high temperature, high strength
materials. Current techniques produce unwanted tensile debits and
fatigue debits.
[0008] Current repair or rework techniques include fusion welding,
plasma spraying, plating and brazing. Fusion welding unfortunately
creates strain age cracking (particularly with the nickel-based
superalloys) and embrittlement (particularly with the highly
alloyed, alpha beta titanium materials) in these materials. Plasma
spray and plating likewise create excessive residual stress in
these materials due to the high thickness build-ups. Clearly, these
techniques are not compatible with high temperature, high strength
materials. Thus, a need exists for a repair or rework method that
is compatible with the aforementioned high temperature, high
strength materials.
DISCLOSURE OF THE INVENTION
[0009] Thus, it is an object of the present invention to provide a
new and improved method of repairing or reworking a part.
[0010] It is a further object of the present invention to provide a
repair/rework method compatible with high temperature, high
strength materials.
[0011] It is a further object of the present invention to provide a
repair/rework method that retains the strength capability of the
original part.
[0012] It is a further object of the present invention to provide a
repair/rework method that retains the fatigue capability of the
original part.
[0013] It is a further object of the present invention to provide a
repair/rework method that achieves uniform deformation
characteristics.
[0014] It is a further object of the present invention to provide a
repair/rework method that does not dimensionally distort the
part.
[0015] It is a further object of the present invention to provide a
repair/rework method that does not metallurgically damage the
part.
[0016] It is a further object of the present invention to provide a
repair/rework method that does not affect the performance of the
engine.
[0017] It is a further object of the present invention to provide a
repair/rework method capable of repairing/replacing a dovetail slot
on a multi-stage drum rotor comprised of a high strength alloy
which cannot be repaired by conventional fusion welding, plasma
spraying, plating or brazing.
[0018] It is a further object of the present invention to provide a
method of joining material.
[0019] It is a further object of the present invention to provide a
method of forge joining material to a part.
[0020] It is a further object of the present invention to reduce
the amount of scrap parts.
[0021] These and other objects of the present invention are
achieved in one aspect by a method of repairing a part, comprising
the steps of: providing a wrought part having a contact area and an
anomaly that renders the part unsuitable; providing a wrought
material having a contact area; heating the contact area of the
material and the contact area of the part; and pressing the contact
area of the material against the contact area of the part. The
material bonds to the part to render the part suitable.
[0022] These and other objects of the present invention are
achieved in another aspect by a part produced by the method steps
of: providing a wrought part having a contact area; providing a
wrought material having a contact area; heating the contact area of
the wrought material and the contact area of the wrought part; and
pressing the contact area of the material against the contact area
of the wrought part. The material bonds to the wrought part.
[0023] These and other objects of the present invention are
achieved in another aspect by a method of making a rotating part of
a gas turbine engine, comprising the steps of: providing a rotating
part made from a wrought material and having a contact area;
providing a piece of wrought material having a contact area;
heating the contact area of the material and the contact area of
the part; and pressing the contact area of the material against the
contact area of the part. The material bonds to the part.
[0024] These and other objects of the present invention are
achieved in another aspect by a method of repairing a rotating disk
or drum rotor of a gas turbine engine, comprising the steps of:
providing a rotating disk or drum rotor made from a wrought
material and having an arrangement of lugs and slots, at least one
of the lugs or the slots having an anomaly thereon; treating the
anomaly to form a contact area; providing a piece of wrought
material having a contact area; heating the contact area of the
material and the contact area of the component; pressing the
contact area of the material against the contact area of the
component so that the material bonds to the component; and treating
the material to provide a desired shape to the disk or drum.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Other uses and advantages of the present invention will
become apparent to those skilled in the art upon reference to the
specification and the drawings, in which:
[0026] FIG. 1a is a front elevational view of a stand used to
perform the method steps of the present invention;
[0027] FIG. 1b is a front elevational view of the stand with a
component of a gas turbine engine placed therein;
[0028] FIG. 2a is a plan view of a fixture that secures to the
stand of FIG. 1a;
[0029] FIG. 2b is a side elevational view of the fixture of FIG.
2a;
[0030] FIG. 3 is a partial perspective view of the engine component
of FIG. 1b;
[0031] FIG. 4 is a detailed, front elevational view of one section
of the engine component of FIG. 3 before performing any of the
method steps of the present invention;
[0032] FIGS. 5-8 are front elevational views of a section of the
engine component at various stages of performing the method steps
of the present invention;
[0033] FIG. 9 is a computer rendering of a 16.times.
photomicrograph of the bond line formed by the method steps of the
present invention; and
[0034] FIG. 10 is a computer rendering of a 200.times. blue tape
photomicrograph of the bond line formed by the method steps of the
present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
[0035] The present invention relates to a method of joining
material. In particular, the method is used to repair or to rework
a part by forge joining additional material thereto.
[0036] FIG. 1a displays an example of a stand 100 that can perform
the method steps of the present invention. material to a part 300.
Although the method steps of the present invention could be
performed on any type of part, the following description
illustrates one preferred application of the present invention
[0037] FIG. 3 displays the preferred part 300, a rotating component
of a gas turbine engine (not shown). The rotating component could
be a disk or a hollow drum rotor. The rotating component receives
one or more stages of blades (not shown) around the perimeter. The
disk/drum has a circumferential arrangement of lugs 301. Slots 303
exist between adjacent lugs 301 to receive a corresponding base
(not shown) of a blade. The disk/drum and blades could be part of
the fan section, compressor section or turbine section of the
engine.
[0038] The specific size, shape or arrangement of the disk/drum is
not directly relevant to the present invention. However, the
material comprising the disk/drum is relevant. The disk/drum should
be a high temperature, high strength, wrought material. Preferably,
the material is not fusion weldable and has a fine grain. Such
materials include nickel-based superalloys (e.g. IN100, MERL 76,
AF2-IDA, UDIMET 700, REN 95) or titanium alloys (e.g.
Ti-6Al-2Sr-4Zr-6Mo, Ti-6Al-4V, Ti-6Al-2Sr-4Zr-2Mo).
[0039] FIG. 4 displays a detailed view of one of the lugs 301 of
the disk/drum. The lug 301 has an anomaly 305 thereon. The ideal
shape of the lug 301 is shown as a phantom line. Therefore, the
anomaly 305 in the figure is a lack of material. Other types of
anomalies, such as a deformation of the material, are possible.
[0040] A variety of situations can cause the anomaly 305 on the
disk/drum. The primary cause of the anomaly 305 is mis-machining of
the disk/drum during manufacture. Damage during manufacture or
during operation of the engine could also cause the anomaly
305.
[0041] The anomaly 305 clearly renders the disk/drum unsuitable for
use in the engine. The method steps of the present invention are
used to perform the necessary repair/rework on the disk/drum so
that the part can be placed in service on the engine. In other
words, the present invention reduces the number of parts that are
scrapped.
[0042] Once recognizing that the anomaly 305 on the part 300
exists, the repair/rework process can begin. One of the steps in
repairing/reworking the disk/drum involves treating the anomaly
305. The preferred method of treating the anomaly 305 comprises
machining the anomalous lug 301 using conventional techniques and
equipment (not shown). Other methods, however, could be used. The
machining step produces a surface suitable for the subsequent steps
of the present invention. As seen in FIG. 5, machining the
anomalous lug 301 produces a contact area 307. Preferably, the
contact area 307 is planar. However, other shapes are possible. The
phantom line in FIG. 5 outlines the ideal shape of the lug.
[0043] Another step in the repairing/reworking of the disk/drum
involves obtaining suitable replacement material for the anomalous
lug 301. FIGS. 2a and 2b display a fixture 200 that includes
suitable replacement material. The fixture 200 has a base 201 for
securing to the stand 100 using suitable fasteners (not shown). The
fixture 200 also has a replacement section 203. As will be
described in more detail in the subsequent steps, at least a
portion of the replacement section 203 will become a part of the
lug 301.
[0044] Since the replacement section 203 becomes part of the lug
301, the amount of material comprising the replacement section 203
should be greater than the amount of material needed to correct the
anomalous lug 301. Although larger, the replacement 203 should have
a shape and size generally similar to the lug 301 in order to
reduce the amount of scrap material produced.
[0045] Preferably, the replacement section 203 could use the same
high temperature, high strength wrought material as the lug 301.
However, the replacement section 203 could use materials that are
different than the lug 301.
[0046] As seen in FIG. 2b, the distal end of the replacement
section 203 includes a sacrificial portion 205. The purpose of the
sacrificial portion 205 will be described in more detail below.
[0047] The distal end of the sacrificial portion 205 includes a
contact area 207. The contact area 207 corresponds to the contact
area 307 formed on the lug 301. Although the contact area 307
preferably has a planar shape, other shapes are possible. The
contact areas 207, 307 should also have the same general size.
[0048] For the remaining steps, the part 300 must be placed in the
stand 100. The earlier steps could either have been performed with
the part 300 installed in the stand 100 or before the part 300 has
been placed in the stand 100.
[0049] Referring to FIG. 1a, the stand 100 has a base 101, sides
103 and an upper section 105. The sides 103 and the upper section
105 define an opening 107 for receiving the part 300. FIG. 1b
displays the part 300 placed within the stand 100. The part 300
rests on correspondingly shaped sections of the sides 103. A bar
109 secured to the base 101 can mount, using suitable fasteners, to
the front of the part 300. The sides 103 and the bar 109 provide
suitable support to the part 300 during the subsequent steps.
[0050] The stand 100 includes a ram 111 mounted to the upper
section 105. Preferably, the anomalous lug 301 on the part 300
secured to the stand 100 is located directly below the ram 111. The
ram 111 could be a conventional hydraulic cylinder. In order to
perform properly, the ram 111 should be at least a 1 ton hydraulic
press.
[0051] The stand 100 also includes a power supply 113. The power
supply 113 can be any conventional device, such as a transformer.
The power supply 113 preferably converts an AC source (not shown)
to DC. The power supply 113 has electrical cables 115 that secure,
using known techniques, to the fixture 200 and to the part 300. As
will be discussed below, the cables 115 allow DC current to flow
between the fixture and the part 300 for resistance heating. In
order to perform properly, the power supply 113 could be a Goodrich
480 Volt, 25 KVA gun-style welding transformer controlled by a
compatible Research, Inc. SCR.
[0052] The stand 100 also includes a temperature sensor 117. The
sensor 117 could have any conventional design sufficient to
determine the high temperature attained by a part heated by the
power supply 113.
[0053] Although not shown, the stand 100 also includes the
necessary electronics and mechanical elements necessary to operate
the ram 111 and the power supply 113 and to receive data from the
temperature sensor 117. The method steps of the present invention
could be performed manually by an operator (not shown) or
automatically using suitable electronics (not shown).
[0054] Although specific parts have been described, the stand 100
could be any suitable frame that can support the part 300 and can
perform the necessary steps of the present invention.
[0055] Another step in the repairing/reworking of the disk/drum
involves using the ram 111 to place the contact surface 207 of the
fixture 200 against the contact surface 307 of the part 300. The
contact surfaces 207, 307 abut and define a joint 309. At this
point, the ram 111 need not apply a large force to the fixture 200.
An amount of force sufficient to retain the fixture 200 against the
part 300 and to allow current to travel across the joint 309 is
preferred. FIG. 6 displays the fixture 200 placed against the part
300.
[0056] The next step in the repairing/reworking of the disk/drum
involves forge joining the fixture 200 to the part 300. Forge
joining has multiple stages. The first stage involves heating the
joint 309. With the cables 115 attached to the fixture 200 and to
the part 300, activating the power supply 113 produces resistance
heating in the joint 309. Aside from the joint 309, the remainder
of the part 300 does not increase significantly in temperature. In
other words, the heating remains localized to the joint 309 and
does not metallurgically affect the remainder of the part 300. The
heating remains localized due to the discontinuity between the
fixture 200 and the part 300 across the contact areas 207, 307. The
discontinuity creates an area with a resistance value higher than
the remaining areas of the part 300.
[0057] The power supply 113 operates to allow the joint 309 to
achieve a suitable bonding temperature. Preferably, power supply
113 heats the joint 309 until the material at the joint 309
achieves a superplastic state. For example, the power supply 113
could heat the joint 309 at a rate of approximately 200.degree.
F./min to the bond temperature. The specific temperature to which
the power supply 113 heats the joint 309 depends on the specific
material of the fixture 200 and the part 300. As an example, an
IN100 material achieves a superplastic state at approximately
1800.degree. F. The sensor 117, seen in FIG. 6 as attached to the
fixture 200 adjacent the joint 309 using conventional techniques,
determines the temperature of the joint 309.
[0058] Upon reaching the desired bond temperature, the power supply
113 will supply adequate power to maintain the joint 309 within the
superplastic temperature range. Using the previous example, the
power supply 113 continues to heat the IN100 material to maintain a
temperature of approximately 1800.degree. F.
[0059] The next stage of the forge joining step involves pressing
the fixture 200 against the part 300. Upon the joint 309 reaching
the desired temperature, the ram 111 activates to drive the fixture
200 towards the part 300. Preferably, the ram 111 rapidly ramps up
hydraulic pressure to a desired load sufficient to bond the fixture
200 to the part 300. For example, the desired bond load for the
IN100 material is approximately 15 ksi.
[0060] The ram 111, while maintaining the desired load, drives the
fixture 200 a sufficient distance towards the part 300 to ensure
that an adequate bond occurs. The upset distance that the ram 111
drives the fixture 200 should be at least the thickness of the
sacrificial portion 205. Actuation of the ram 111 causes the
sacrificial section 205 to expand laterally to occupy areas to the
sides of the joint. The specific upset distance that the ramlll
drives the fixture 200 depends upon the material of the fixture 200
and the part 300. For example, the ram ill should drive an IN100
material a distance of approximately 0.100" at the desired load of
15 ksi.
[0061] Aside from the sides 103 and the bar 109, no other support
exists to reinforce the hollow disk/drum against the forces
produced by the ram 111. Due to the superplastic state of the
material adjacent the joint 309, the forces created during
operation of the ram 111 remain localized to the joint 309. That
is, no substantial forces are transmitted to the remainder of the
disk/drum during operation of the ram 111. Thus, the ram 111 does
not dimensionally distort the remainder of the disk/drum.
[0062] FIG. 7 displays the fixture 200 and the part 300 after the
forge joining step. The replacement section 203 of the fixture has
now bonded to the part 300. The power supply 113 deenergizes to
allow the part 300 to cool. Preferably, the cooling rate exceeds
approximately 200.degree. F./min.
[0063] If necessary, the part could undergo other steps after forge
joining. These steps could help the part obtain the desired
material characteristics. For example, the part could undergo a
soak for a duration of time before cooling. The part could also
undergo an additional localized heat treatment. For example, this
treatment may locally heat the part 300 at approximately 50.degree.
F./min (.+-.25.degree. F./min) to an age temperature of
1350.degree. F. The heat treatment maintains such temperature for
approximately 2 hours. Finally, the heat treatment allows the part
300 to cool to room temperature at a rate at least equivalent to
air cooling.
[0064] FIG. 7 shows that the amount of material needed to correct
the anomalous lug 301 is less than the amount of material
comprising the replacement section 203. As a consequence, another
step in the repairing/reworking of the disk/drum involves removing
the surplus material. Preferably, the surplus material is machined
using conventional techniques and equipment (not shown). Other
methods, however, could be used. FIG. 8 displays the part 300 after
machining away the surplus material. The lug 301 no longer has the
anomaly.
[0065] Importantly, the method steps of the present invention
produce a replacement lug 301 that has the same metallurgical
characteristics as an original lug 301. In other words, the
replacement lug 301 exhibits approximately the same strength
capability, fatigue capability and deformation characteristics as
the original lug 301. As seen in FIG. 8, the naked eye cannot
discern a bond line at the joint 309 between the replacement
section 203 and the part 300.
[0066] Only under magnification can one discern a bond line 311.
FIG. 9 is a computer rendering of a low magnification (16.times.)
photomicrograph of a bond line 311 using Kalling's etchant. The
photomicrograph displays the presence of the bond line 311 at the
joint 309 between the replacement section 203 and the part 300.
FIG. 10 is a computer rendering of a photomicrograph (200.times.)
of the bond line 311 using Kaling's etchant. The photomicrograph
confirms the bond line 311 at the joint 309 between the replacement
section 203 and the part 300.
[0067] To ensure that the bond line 311 does not affect the
strength of the replacement lug, a test was conducted to forge join
a replacement lug to a scrap high pressure compressor disk/drum.
Both parts were made from a wrought IN-100 material. Specifically,
the experiment forge joined the replacement lug to the disk/drum by
upsetting the replacement lug 0.100" at a bond temperature of
1800.degree. F. and at a bond load of 15 ksi.
[0068] The test then subjected the replacement lug and an original
lug (i.e. a lug without an anomaly) to a tensile load using
conventional equipment. The test revealed that the replacement lug
and the original lug failed at approximately the same load even
though each lug had a different failure location. In fact, the
original lug failed before the replacement lug (13,080 lbs and
13230 lbs, respectively). Therefore, the test confirmed that the
replacement lug exhibited the same strength characteristic as the
original wrought part.
[0069] In order to establish the preferred parameters for the
methods of the present invention (such as those used in the
aforementioned test), multiple experiments were conducted. The
experiments forge joined two IN-100 rods (0.5" diameter, 3" length)
together using the parameters specified in the table below.
1TABLE 1 Tensile Ultimate Bond Bond Soak Cool Age Test Yield
Tensile Area Temp Load Upset Temp Rate Heat Temp Strength Strength
Elongation Reduction .degree. F. ksi Inch .degree. F. .degree.
F./min Treat .degree. F. ksi Ksi % % 1800 30 0.100 2065 15 Local 75
155.9 197.0 8.5 11.6 1800 15 0.090 None 75 Isothermal 75 174.8
177.0 2.5 7.0 1800 15 0.090 None 75 Isothermal 75 174.2 183.7 4.5
6.3 1800 15 0.090 None 75 Isothermal 75 174.5 205.9 9.0 10.8 1800
30 0.100 2065 15 Local 800 150.6 184.4 7.8 12.3 1800 30 0.100 2065
15 Local 800 149.6 168.6 4.9 10.1 1800 15 0.090 None 75 Isothermal
800 153.0 205.2 13.4 15.0 1900 25 0.110 1850 150 Local 1000 151.1
158.0 2.2 3.7 1900 25 0.110 1850 150 Local 1000 152.9 173.2 5.1
10.9 1900 25 0.110 1850 150 Local 1100 152.4 166.3 3.3 7.8 1900 25
0.110 1850 150 Local 1100 152.5 168.8 3.3 7.8 1900 25 0.110 1850
150 Local 1100 156.8 186.5 6.7 11.6 1900 25 0.175 2065 150 Local
1100 144.9 194.2 15.3 21.6 1900 25 0.175 2065 150 Local 1100 146.4
191.6 14.5 22.1 1900 25 0.175 1850 150 Local 1100 146.7 188.0 11.7
17.8 1900 25 0.200 None 150 Local 1100 155.6 202.6 19.5 24.7 1900
25 0.200 1850 150 Local 1100 158.7 205.3 17.5 23.6 1900 25 0.175
2065 150 Local 1200 153.6 188.5 13.8 17.3 1800 30 0.100 2065 15
Local 1300 156.1 163.9 1.5 3.9 1800 15 0.090 None 75 Isothermal
1300 162.3 162.3 0.8 3.0 1800 15 0.090 None 75 Isothermal 1300
162.3 166.9 1.7 3.1 1800 15 0.090 None 75 Isothermal 1300 152.7
158.9 1.9 3.9 1800 15 0.090 None 75 Isothermal 1300 153.7 165.7 3.0
7.0
[0070] While the present invention has been described above as a
repair/rework method to remove an anomaly from a part, the present
invention could also be used in the original manufacture of the
part 300. In such a situation, the disk/drum could be formed
without the lugs 301 (e.g. the disk/drum has contact areas 307 such
as seen in FIG. 6). The forge joining step would then add the lugs
301 to the disk/drum.
[0071] The present invention has been described in connection with
the preferred embodiments of the various figures. It is to be
understood that other similar embodiments may be used or
modifications and additions may be made to the described embodiment
for performing the same function of the present invention without
deviating therefrom. Therefore, the present invention should not be
limited to any single embodiment, but rather construed in breadth
and scope in accordance with the recitation of the appended
claims.
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