Rough forging is a manufacturing method mainly used for the preliminary forming of large pieces of metal or alloy materials. It is usually processed by hammering or pressing, heating the blank to a high temperature. Rough forging turbine parts is at a critical primary stage in the entire manufacturing process. Rough forging can improve the internal quality of the material and make the metal have better structure and performance in the subsequent precision processing process.
The forging process can eliminate pores and shrinkage holes in the material, improve the density of the material, and enhance its mechanical properties.
The heat treatment and pressure action during the rough forging process help to refine the grains, make the internal structure of the material more uniform, reduce internal defects, and improve overall strength and toughness.
Rough forging can roughly form the blank to a shape close to the final design, reduce the workload of subsequent precision processing, and improve material utilization.
Through high temperature forging and slow cooling treatment, the microstructure of the material can be improved, and its high temperature strength, wear resistance and corrosion resistance can be improved.
The rough forging process can process large-sized and complex-shaped blanks, which is suitable for manufacturing large and high-performance turbine parts.
Rough forged turbine parts such as discs and shafts are key structural parts for support and connection in turbines, and withstand high temperature and high pressure working environments.
Rough forged turbine blades, hubs and other accessories need to withstand the impact and wear of high temperature combustion gas, convert the energy of high temperature and high pressure gas into mechanical energy, and drive the turbine to rotate.
Turbine parts such as guide vanes and diffusers guide and stabilize airflow through precise preliminary forming, improving overall efficiency and performance.
The rough forging process improves the high temperature strength and creep resistance of the material, enabling these accessories to operate stably and for a long time under extreme working conditions of the turbine.
Steps and methods of rough forging process
Heat the metal billet to a certain temperature to achieve the conditions required for plastic deformation.
The billet is initially formed into the required geometric shape by hammering, pressing or rolling.
Rough forging can roughly form the blank to a shape close to the final design, reduce the workload of subsequent precision processing, and improve material utilization.
Multi-directional forging of metal by free forging hammer or impact forging machine, suitable for large size and small batch production.
Use die to accurately shape metal, suitable for mass production, mostly used for complex shape accessories.
Used to manufacture annular or cylindrical turbine accessories, such as turbine disks and compressor disks.
Purpose: Used as the core component of turbine engines, bearing high temperature, high pressure and centrifugal force caused by high-speed rotating blades.
Features: High strength, high toughness, and long-term stable operation under extreme conditions.
Purpose: Convert the energy of gas into mechanical energy to drive the operation of aircraft engines.
Features: High temperature resistance, corrosion resistance, high material density, and excellent fatigue resistance.
Purpose: Used in gas power plants, high-temperature and high-pressure gas generated by burning natural gas or other fuels drives turbines to generate electricity.
Features: Turbine blades, turbine disks and other precision parts with high temperature strength and high durability are required.
Purpose: Use high-temperature and high-pressure steam to drive turbines to generate electricity in thermal power plants and nuclear power plants.
Features: High creep resistance and excellent high temperature fatigue resistance ensure continuous operation reliability.
Use: Used in propulsion systems for military and civilian ships, using high temperature and high pressure gas to drive the turbine to rotate.
Features: High corrosion and fatigue resistance, able to operate reliably for a long time in marine environments.
Use: Used for transportation and processing in offshore oil and gas production.
Features: Materials and designs that require efficient operation in extremely high pressure and corrosive environments.
Use: Used in various industrial drive equipment, such as gas compression or power generation equipment in metallurgical and chemical processes.
Features: Requires high wear resistance and high temperature resistance, guides air flow and energy conversion.
Use: Used in industrial fluid delivery and gas compression systems.
Features: High-performance rough forging components improve the durability and efficiency of such equipment.
Use: Turbochargers for automobile engines increase engine power by increasing intake volume and combustion efficiency.
Features: Rough forged rotors and compressor impellers can withstand high temperature and high speed conditions, improving engine performance and efficiency.
Use: In natural gas transportation and oil refining, rough-forged compressor impellers and discs are used to compress gas efficiently.
Features: High-pressure resistance, corrosion resistance, and high fatigue resistance.
Castings are prone to defects such as pores, shrinkage and segregation, while rough forging eliminates these internal defects through high temperature and external force, making forgings have higher tensile strength, impact toughness and fatigue life.
Rough forging can improve the density and uniformity of materials, avoiding shrinkage and segregation during the cooling process of castings.
Through the rough forging process, the metal grains are refined and the internal structure is more uniform, which effectively improves the high-temperature creep resistance and corrosion resistance of the material.
Residual stress is easily generated inside the metal during the casting process, while in the rough forging process, high-temperature forging and slow cooling can effectively eliminate the residual stress inside the material, improving the stability and reliability of the product.
Due to fewer internal defects, uniform structure and stress elimination, rough forging accessories show higher stability and long life during use, and are suitable for key components in high-stress and high-temperature environments.
Compared with the casting process, the rough forging has higher dimensional accuracy and better surface quality, which reduces the workload of subsequent machining and improves production efficiency.
Function: Convert the energy of gas or steam into mechanical energy and drive the turbine by rotation.
Features: It needs to have extremely high temperature resistance, corrosion resistance and fatigue resistance to withstand high temperature, high pressure and high-speed rotation environment.
Application: Widely used in aircraft engines, industrial gas turbines and steam turbines.
Function: Used in turbochargers to compress air through high-speed rotation to increase the engine’s intake volume and efficiency.
Features: It needs to have high strength, high rigidity and high temperature resistance to cope with the huge centrifugal force generated by high-speed operation.
Application: Widely used in the boosting system of automobile engines, aircraft engines and industrial equipment.
Function: Fix multiple turbine blades together to form a complete turbine wheel to maintain structural stability and airflow uniformity.
Features: It needs to have high wear resistance and precise dimensions to ensure the balance and sealing performance of the turbine.
Application: Usually used in large gas turbines and steam turbines.
Function: Support and connect turbine blades, withstand the huge centrifugal force and stress generated by high temperature, high pressure and high-speed rotation.
Features: It needs to have extremely high strength and toughness, excellent high temperature resistance and fatigue resistance, and the material needs to be dense and defect-free.
Application: Widely used in aircraft engines, power generation gas turbines and steam turbines.
Function: Burning fuel produces high-temperature and high-pressure gas, which drives the turbine blades to rotate.
Features: It needs to have extremely high temperature resistance, thermal shock resistance and corrosion resistance to ensure the density and durability of the material.
Application: Widely used in aircraft engines and industrial gas turbines.
Function: Guide the flow of gas and accelerate it so that it enters the turbine rotor blades at the best angle and speed to convert kinetic energy.
Features: It needs high-temperature strength, corrosion resistance and high wear resistance to cope with high-speed airflow and high temperature and high pressure environment.
Application: Widely used in gas turbines and aircraft engines to ensure airflow stability and efficiency.
Function: Fix and guide the airflow to optimize the flow path before entering the rotor blades.
Features: High durability, good thermal fatigue performance and precise dimensional control are required.
Application: Used in turbine drive systems, including aircraft engines and industrial turbines.
Function: Convert the energy of high-temperature and high-pressure airflow into mechanical energy to drive the rotor blades to rotate.
Features: Extremely high-temperature resistance, high strength and fatigue resistance are required to ensure safe operation and long life.
Application: Widely used in aircraft engines, industrial turbines, power generation equipment, etc.
High strength and durability
Excellent fatigue performance
Complex shape manufacturing capability
Material diversity