Methods for producing forged products and other worked products

Patent metadata

Field	Value
Publication number	US-2017203355-A1
Application number	US-201715407987-A
Country	US
Kind code	A1
Filing date	Jan 17, 2017
Priority date	Jan 14, 2016
Publication date	Jul 20, 2017
Grant date	—

Abstract

Generally, the present disclosure is directed various embodiments to additively manufacture AM preforms to reduce, prevent, and/or eliminate defects that occur in post processing operations (e.g. forging, shot peening, machining, or other post processing operations).

First claim

What is claimed is:

1 . A method comprising:
(a) additively manufacturing a metal shaped-preform from an additive manufacturing feedstock; (b) concomitant with (a), using a bead deposition strategy to modify a bead path, whereby the combination of (a) and (b) provide the metal shaped preform configured with a smoothed external surface having non-stepped walls as compared to the metal shaped preform without such bead deposition strategy; and (c) performing at least one post processing operation on the metal shaped preform to form a final formed product, whereby, due to (b), the final formed product has reduced post processing operation defects as compared to without (b).

2 . The method of claim 1 , wherein the bead deposition strategy comprises path planning of the bead path.

3 . The method of claim 2 , wherein path planning is selected from the group consisting of:
a. a non-linear build path around the interior of a part build; b. a non-linear build path around the perimeter of a part build; c. an overlapping bead deposition in the build direction, when comparing a first AM deposition layer to a subsequent AM deposition layer, wherein each deposition layer is configured from a plurality of beads, such that between the first AM deposition layer and the subsequent AM deposition layer, a subsequent layer bead does not completely overlap with a first layer bead, and d. combinations thereof.

4 . The method of claim 1 , wherein the bead deposition strategy comprises path planning, wherein a first bead in a first AM build layer overlaps at least a portion but not entirely with a subsequent bead in a subsequent AM build layer, wherein the subsequent bead is in contact with the first bead.

5 . The method of claim 1 , wherein the post processing operation is selected from the group consisting of: forging, thermally treating and machining, machining, shot peening, annealing, and combinations thereof.

6 . The method of claim 1 , wherein the additively manufacturing is completed with a directed energy deposition additive machine.

7 . The method of claim 6 , wherein the direct energy deposition additive machine is selected from the group consisting of: a Sciaky machine, plasma arc machine, a wire feed AM machine, and combinations thereof.

8 . The method of claim 1 , wherein the post processing operation is forging and the final formed product is free from forging defects selected from the group consisting of: folds, cavities, and combinations thereof.

9 . The method of claim 1 , further comprising:
a. machining the final forged part to provide a finished part.

10 . The method of claim 1 , wherein the metal preform comprises at least one of titanium, titanium alloy, titanium aluminide, aluminum, nickel, steel, and stainless steel.

11 . The method of claim 1 , wherein the bead deposition strategy is configured in a vertical direction such that the vertical surfaces are free from defect-causing discontinuities in the post processing operation.

12 . The method of claim 1 , wherein the bead deposition strategy is configured in a horizontal direction such that the horizontal surfaces are free from defect-causing discontinuities in the post processing operation.

13 . A method, comprising:
a. additively manufacturing a metal shaped-preform from an additive manufacturing feedstock using a direct energy deposition additive machine; b. utilizing path planning deposition strategy to promote a non-stepped perimeter of the metal shaped preform, and c. forging the metal shaped preform to form a final forged product, whereby via (b) the final forged product is substantially free from forging defects including at least one of: laps, cavities, folds, cold shuts, and combinations thereof.

14 . The method of claim 13 , wherein path planning further comprises utilizing a modified bead deposition in successive layers of the metal shaped preform such that the bead deposition layers are non-conforming to provide a different build pattern layer-by-layer within the metal shaped preform.

15 . The method of claim 13 , wherein path planning further comprises utilizing a modified bead deposition in successive layers of the metal shaped preform such that the bead deposition layers are overlapping by less than 100%.

16 . The method of claim 15 , wherein bead overlap is less than 80% between two beads of successive AM build layers.

17 . The method of claim 15 , wherein the bead overlap is less than 50% between two beads of successive AM build layers.

18 . The method of claim 15 , wherein the bead overlap is less than 30% between two beads of successive AM build layers.

19 . The method of claim 13 , whereby the metal shaped preform is configured with a smoothed surface, characterized by the absence of jogs and steps in the build height direction, configured in the direction normal from the build plane.

20 . The method of claim 13 , wherein the path planning deposition strategy is configured in a vertical direction such that the vertical surfaces are free from defect-causing discontinuities in the forging step.

21 . The method of claim 13 , wherein the path planning deposition strategy is configured in a horizontal direction such that the horizontal surfaces are free from defect-causing discontinuities in the forging step.

22 . The method of claim 13 , the forging step comprises a single die forging step.

23 . The method of claim 13 , wherein the metal preform comprises at least one of titanium, titanium alloy, titanium aluminide, aluminum, nickel, steel, and stainless steel.

24 . The method of claim 13 , wherein the forging step comprises:
a. heating the metal shaped-preform to a stock temperature; and b. contacting the metal shaped-preform with a forging die.

25 . The method of claim 13 , wherein after the utilizing step (b), working the metal shaped-preform into a final worked product via at least one of: (i) rolling, (ii) ring rolling, (iii) ring forging, (iv) shaped rolling, (v) extruding, and (vi) combinations thereof.

26 . The method of claim 13 comprising, after the forging step (c), annealing the final forged product.

Assignees

• Arconic Inc

Inventors

• Satoh Gen
• Myers Jr Daniel M
• Bodily Brandon H

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B23K15/0086

  welding for purposes other than joining, e.g. build-up welding · CPC title

• G05B19/4099

  Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing · CPC title

• B23K9/04

  Welding for other purposes than joining, e.g. built-up welding · CPC title

• B23P15/00

  Making specific metal objects by operations not covered by a single other subclass or a group in this subclass · CPC title