Rolls-royce Corporation

Rolls-royce North American Technologies Inc.

Eugene Sun

Gangshu Shen

Robert Anthony Ress, Jr

Timothy Fuesting

Mark E Bartolomeo

Brian Drier

Stephanie M Janicek

Stephanie Janicek

Robert Ress Iii

The disclosure describes example systems and techniques for controlling microstructure of a superalloy substrate by controlling temperature during forging and using multiple die forging stages to formation of grain boundary phases of the superalloy, and components formed by such example systems and techniques. The method includes heating a substrate to within a forging temperature range. The substrate includes a nickel-based superalloy, and the forging temperature range is below an eta phase solvus temperature of the substrate. The method includes applying a plurality of die forging stages to the substrate to form a component preform. The method includes maintaining the substrate within the forging temperature range during application of the plurality of die forging stages and cooling the component preform.

Controlled microstructure for superalloy components

An example system may include a computing device including a finite element analysis module solving for a finite element model representing a component including a metal or an alloy and including a plurality of respective elements. The finite element analysis module may solve a respective stress Sand a respective temperature Tat each respective element during the predetermined cooling operating. The finite element analysis module may determine a respective impact energy Ebased on the temperature Tand cooling rate, using a predetermined cooling rate-dependent energy relationship that relates a temperature of the metal or the alloy to an impact energy, determine a respective weakness index W=[A&#xd7;E/S](A being a predetermined constant, n being a predetermined real number greater than or equal to 1), and identify a respective element having a minimum weakness index less than a predetermined weakness index threshold as a cracking-prone element.

Predicting cracking in cooled metal or alloy components

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Carmel, IN, United States of America

Eugene Sun