Articles, systems, and methods for forging alloys

Abstract

A system and method of processing an alloy ingot or other alloy workpiece to reduce thermal cracking and reduce friction between the workpiece and the forging die may generally comprise positioning a multi-layer pad between the workpiece and the forging die. An article for processing an alloy ingot or other alloy workpiece to reduce thermal cracking also is disclosed. The present disclosure also is directed to an alloy workpieces processed according to the methods described herein, and to articles of manufacture including or made from alloy workpieces made according to these methods.

What is claimed is: 
     
         1 . A multi-layer pad for use during a forging operation, wherein the multi-layer pad comprises:
 a first lubricative layer;   a second lubricative layer; and   a first insulative layer, wherein the first insulative layer is positioned intermediate the first and second lubricative layers, and wherein at least one of the first and second lubricative layers comprises fiberglass.   
     
     
         2 . The multi-layer pad of  claim 1 , wherein the first lubricative layer further comprises a workpiece-contacting surface, and wherein the second lubricative layer further comprises a die-contacting surface. 
     
     
         3 . The multi-layer pad of  claim 1 , wherein the first insulative layer comprises ceramic fibers. 
     
     
         4 . The multi-layer pad of  claim 1 , wherein the first insulative layer comprises KAOWOOL. 
     
     
         5 . The multi-layer pad of  claim 1 , wherein a coefficient of friction of the first lubricative layer and a coefficient of friction of the second lubricative layer are less than a coefficient of friction of the first insulative layer. 
     
     
         6 . The multi-layer pad of  claim 1 , wherein a thermal conductivity of the first insulative layer is less than a thermal conductivity of the first lubricative layer and a thermal conductivity of the second lubricative layer. 
     
     
         7 . The multi-layer pad of  claim 1 , further comprising a fastener adapted to fasten at least the first and second lubricative layers relative to each other. 
     
     
         8 . The multi-layer pad of  claim 1 , wherein the first and second lubricative layers form a sleeve for the insulative layer. 
     
     
         9 . A method for processing an alloy workpiece, comprising:
 heating the alloy workpiece to a temperature above an ambient temperature;   positioning a multi-layer pad between the alloy workpiece and a die, wherein the multi-layer pad comprises a lubrication layer and a thermal resistance layer, wherein the lubrication layer comprises fiberglass; and   hot working the alloy workpiece.   
     
     
         10 . The method of  claim 9 , wherein hot working the alloy workpiece comprises applying a force with the die to the alloy workpiece to deform the alloy workpiece. 
     
     
         11 . The method of  claim 10 , wherein applying a force with the die to the alloy workpiece to deform the alloy workpiece comprises upset forging the alloy workpiece. 
     
     
         12 . The method of  claim 9 , further comprising positioning a plurality of multi-layer pads between the alloy workpiece and at least one die. 
     
     
         13 . The method of  claim 9 , further comprising pre-forming the alloy workpiece. 
     
     
         14 . The method of  claim 9 , further comprising fabricating an article from the hot worked alloy workpiece, wherein the article is selected from the group consisting of a jet engine component, a land based turbine component, a valve, an engine component, a shaft, and a fastener. 
     
     
         15 . The method of  claim 9 , wherein heating the alloy workpiece to a temperature above the ambient temperature comprises heating the alloy workpiece above a recrystallization temperature of the alloy and below the melting point temperature of the alloy. 
     
     
         16 . The method of  claim 9 , wherein the alloy workpiece comprises one of an ingot, a billet, a bar, a plate, a tube, and a sintered pre-form. 
     
     
         17 . The method of  claim 9 , wherein the alloy workpiece comprises a crack sensitive alloy. 
     
     
         18 . The method of  claim 9 , wherein the alloy workpiece comprises a material selected from the group consisting of Alloy 718 (UNS No. N07718), Alloy 720 (UNS No. N07720), Rene 41 alloy (UNS No. N07041), Rene 65 alloy, Rene 88 alloy, WASPALOY® alloy (UNS No. N07001), and INCONEL® 100 alloy. 
     
     
         19 . The method of  claim 9 , wherein a coefficient of friction of the lubrication layer is less than a coefficient of friction of the thermal resistance layer. 
     
     
         20 . The method of  claim 9 , wherein the thermal resistance layer comprises KAOWOOL. 
     
     
         21 . The method of  claim 20 , wherein a thermal resistance of the thermal resistance layer is greater than a thermal resistance of the lubrication layer. 
     
     
         22 . An alloy workpiece processed by the method of  claim 9 . 
     
     
         23 . A hot worked article formed from an alloy workpiece by a process comprising the method of  claim 9 .