Thermomechanical treatment for nickel base superalloys

Claim 2

A thermomechanical process for producing a microstructure of elongated grains in nickel base superalloys, which possess a gamma prime second phase and a gamma prime solvus temperature, including the steps of: a. providing the nickel base superalloy in a super-plastic condition; b. hot deforming the superalloy under the following conditions: a deformation temperature below but within about 250°F of the gamma prime solvus, a deformation rate of less than about 1.0 in/in/min, and a total deformation amount in excess of about 10%; c. progressively heating the article in a thermal gradient which moves relative to the article with the thermal gradient having a steepness of at least 50°F/in measured at the gamma prime solvus temperature, and a hot end temperature greater than the gamma prime solvus temperature but less than the melting temperature.

Claim 3

A process as in claim 1 wherein the hot deformation conditions fall within the region bounded by the line segments Q--T, Q--R, Q--S, S--R, S--T, and T--R in FIG. 2.

Claim 4

A thermomechanical process for producing a microstructure of elongated grains in nickel base superalloys, which possess a gamma prime second phase and a gamma prime solvus temperature, including the steps of: a. providing a mass of powder of the superalloy; b. hot compacting the powder; c. placing the compacted powder in a temporary condition of super-plasticity by hot working an amount equal to about a 4:1 area reduction at a temperature below, but within 450°F of the gamma prime solvus; d. hot deforming the super-plastic superalloy under the following conditons: a temperature below but within about 250°F of the gamma prime solvus, a deformation rate of less than about 1.0 in/in/min, and a total deformation amount in excess of about 10%, whereby a uniform dislocation density and a propensity for abnormal grain growth results; e. progressively heating the article in a thermal gradient which moves relative to the article, with the thermal gradient having steepness of at least about 50°F/in measured at the gamma prime solvus temperature, and a hot end temperature greater than the gamma prime solvus temperature but less than the melting temperature.

Claim 5

A thermomechanical process for producing a microstructure of elongated grains in nickel base superalloys, which possess a gamma prime second phase and a gamma prime solvus temperature, including the steps of: a. providing a mass of powder of the superalloy; b. hot compacting the powder; c. placing the compacted powder in a temporary condition of super-plasticity by hot working an amount equal to about a 4:1 area reduction at a temperature below, but within 450°F of the gamma prime solvus; d. hot deforming the super-plastic superalloy under the following conditons: a temperature below but within about 250°F of the gamma prime solvus, a deformation rate of less than about 1.0 in/in/min, and a total deformation amount in excess of about 10%, whereby a uniform dislocation density and a propensity for abnormal grain growth results; e. progressively heating the article in a thermal gradient which moves relative to the article, with the thermal gradient having steepness of at least about 50°F/in measured at the gamma prime solvus temperature, and a hot end temperature greater than the gamma prime solvus temperature but less than the melting temperature.

Claim 6

A thermomechanical process for producing a complex nickel base superalloy article having a cross-sectional area which varies by a factor of at least 2:1 and also having a microstructure of elongated grains which include the steps of: a. providing the nickel base superalloy in a super-plastic condition; b. hot deforming the superalloy to a complex shape under the following conditions: a temperature below but within about 250°F of the gamma prime solvus, a deformation rate of less than about 1.0 in/in/min, and a total deformation amount in excess of about 10%; c. progressively heating the shaped article in a thermal gradient which moves relative to the article with the thermal gradient having a steepness of at least 50°F/in measured at the gamma prime solvus temperature, and a hot end temperature greater than the gamma prime solvus temperature but less than the melting temperature.

Claim 7

A thermomechanical process for producing a complex nickel base superalloy article having a cross-sectional area which varies by a factor of at least 2:1 and also having a microstructure of elongated grains which include the steps of: a. providing the nickel base superalloy in a super-plastic condition; b. hot deforming the superalloy to a complex shape under the following conditions: a temperature below but within about 250°F of the gamma prime solvus, a deformation rate of less than about 1.0 in/in/min, and a total deformation amount in excess of about 10%; c. progressively heating the shaped article in a thermal gradient which moves relative to the article with the thermal gradient having a steepness of at least 50°F/in measured at the gamma prime solvus temperature, and a hot end temperature greater than the gamma prime solvus temperature but less than the melting temperature.