Enhanced surface structure

Abstract

A formed material can include a composition having a non-recrystallized portion and a recrystallized layer of the composition having predetermined depth, the recrystallized layer forming at least part of a surface of the composition that overlays the non-recrystallized portion. A method of forming a material having an at least partially recrystallized layer can include forming a composition into a predetermined shape having a surface, wherein the forming leaves the surface of the composition in a non-recrystallized state. The method can also include determining a desired depth of at least a portion of a recrystallized layer at the surface and recrystallizing at least a portion of the surface of the composition to form the recrystallized layer to the desired depth.

What is claimed is: 
     
         1 . A formed material, comprising:
 a composition including a non-recrystallized portion; and   a recrystallized layer of the composition having predetermined depth, the recrystallized layer forming at least part of a surface of the composition that overlays the non-recrystallized portion.   
     
     
         2 . The formed material of  claim 1 , wherein the recrystallized layer is uniform in depth. 
     
     
         3 . The formed material of  claim 1 , wherein the depth of the recrystallized layer is about 0.005 inches to about 0.025 inches. 
     
     
         4 . The formed material of  claim 1 , wherein the recrystallized layer includes a smaller grain size than a non-recrystallized portion of the composition. 
     
     
         5 . The formed material of  claim 1 , wherein the formed material is a turbomachine component. 
     
     
         6 . A method of forming a material having an at least partially recrystallized layer, comprising:
 forming a composition into a predetermined shape having a surface, wherein the forming leaves the surface of the composition in a non-recrystallized state;   determining a desired depth of at least a portion of a recrystallized layer; and   recrystallizing at least a portion of the surface of the composition to form the recrystallized layer to the desired depth.   
     
     
         7 . The method of  claim 6 , wherein the recrystallizing step further includes heat treating the composition after a controlled plastic deformation of at least a portion of the surface of the composition to uniformly form the recrystallized layer. 
     
     
         8 . The method of  claim 6 , wherein the controlled plastic deformation includes at least one of shot-peening, controlled surface blasting, laser shot-peening, ultrasonic peening, explosion forming, or burnishing. 
     
     
         9 . The method of  claim 6 , further comprising cleaning the composition by shot-blasting the composition after forming. 
     
     
         10 . The method of  claim 6 , further including precipitating at least one phase of the material by heat treating the composition to a desired temperature after forming. 
     
     
         11 . The method of  claim 9 , further including precipitating at least one phase of the material by heat treating the composition to at least one suitable temperature that is configured to precipitate the at least one phase after or during cleaning. 
     
     
         12 . The method of  claim 6 , wherein the forming step includes casting. 
     
     
         13 . A method, comprising:
 casting a material into a cast having predetermined shape;   removing the cast from the mold;   after removing the cast from the mold, cleaning the cast by shot-blasting;   after cleaning the cast by shot blasting, cold working a surface of the cast to facilitate recrystallization to desired depth; and   after cold working the surface of the cast to a desired depth, heat treating the cast to a suitable temperature to complete uniform recrystallization of the surface of the cast to a smaller grain size than the non-recrystallized portion.   
     
     
         14 . The method of  claim 13 , further comprising heat treating the cast at a suitable temperature to precipitate a phase of the material after removing the cast from the mold and before plastically deforming the surface of the cast to a desired depth.