Method of processing a multiple alloy rotor
First Claim
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1. A method for processing a rotor forging, the method comprising the steps of:
- casting an ingot to have at least first and second ingot regions axially aligned within the ingot, the first and second ingot regions being formed of different alloys that intermix during casting to define a transition zone between the first and second ingot regions, the transition zone having a composition that differs from and varies between the first and second ingot regions;
forging the ingot to produce a rotor forging containing first and second forging regions and a transition zone therebetween corresponding to the first and second ingot regions and the transition zone of the ingot such that the first and second forging regions are formed of the different alloys and the transition zone of the rotor forging has a composition that differs from and varies between the first and second forging regions, the first and second forging regions and the transition zone therebetween being axially aligned along a geometric centerline of the rotor forging;
ascertaining boundary points of the transition zone within the rotor forging to define a plurality of two-dimensional cross-sectional shapes of the transition zone; and
thenusing the plurality of two-dimensional cross-sectional shapes to produce a three-dimensional approximation of the shape of the transition zone within the rotor forging.
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Abstract
A method of processing a rotor. The rotor is formed by casting an ingot to have first and second regions formed of different alloys that intermix during casting to define a transition zone therebetween. The ingot is forged to yield a rotor forging that contains axially-aligned first and second alloy regions and a transition zone therebetween. A three-dimensional approximation of the transition zone is generated, which can be used to predict the effects of the transition zone on the dynamic performance of a rotor machined from the forging.
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Citations
20 Claims
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1. A method for processing a rotor forging, the method comprising the steps of:
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casting an ingot to have at least first and second ingot regions axially aligned within the ingot, the first and second ingot regions being formed of different alloys that intermix during casting to define a transition zone between the first and second ingot regions, the transition zone having a composition that differs from and varies between the first and second ingot regions; forging the ingot to produce a rotor forging containing first and second forging regions and a transition zone therebetween corresponding to the first and second ingot regions and the transition zone of the ingot such that the first and second forging regions are formed of the different alloys and the transition zone of the rotor forging has a composition that differs from and varies between the first and second forging regions, the first and second forging regions and the transition zone therebetween being axially aligned along a geometric centerline of the rotor forging; ascertaining boundary points of the transition zone within the rotor forging to define a plurality of two-dimensional cross-sectional shapes of the transition zone; and
thenusing the plurality of two-dimensional cross-sectional shapes to produce a three-dimensional approximation of the shape of the transition zone within the rotor forging. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method for processing a rotor forging, the method comprising the steps of:
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producing a rotor forging specimen by; casting an ingot specimen to have at least first and second ingot specimen regions axially aligned within the ingot specimen, the first and second ingot specimen regions being formed of different alloys that intermix during casting to define a transition zone between the first and second ingot specimen regions, the transition zone having a composition that differs from and varies between the first and second ingot specimen regions; forging the ingot specimen to produce a rotor forging specimen containing first and second forging specimen regions and a specimen transition zone therebetween corresponding to the first and second ingot specimen regions and the transition zone of the ingot such that the first and second forging specimen regions are formed of the different alloys and the transition zone of the rotor forging specimen has a composition that differs from and varies between the first and second forging specimen regions, the first and second forging specimen regions and the transition zone therebetween being axially aligned along a geometric centerline of the rotor forging specimen; ascertaining boundary points of the transition zone within the rotor forging specimen to define a plurality of two-dimensional cross-sectional shapes of the transition zone within the rotor forging specimen; and using the plurality of two-dimensional cross-sectional shapes of the transition zone within the rotor forging specimen to produce a three-dimensional contour of the shape of the transition zone within the rotor forging specimen; producing a rotor forging in accordance with the casting and forging steps performed to produce the rotor forging specimen, whereby the rotor forging contains first and second regions and a transition zone therebetween, the first and second regions are formed of the different alloys, the transition zone of the rotor forging has a composition that differs from and varies between the first and second regions, and the first and second regions and the transition zone therebetween are axially aligned along a geometric centerline of the rotor forging; ascertaining boundary points of the transition zone within the rotor forging to define a plurality of two-dimensional cross-sectional shapes of the transition zone; using the three-dimensional contour of the shape of the transition zone within the rotor forging specimen and the boundary points of the transition zone within the rotor forging to produce a three-dimensional approximation of the shape of the transition zone within the rotor forging; using the three-dimensional approximation of the shape of the transition zone within the rotor forging to establish a geometric centerline of the transition zone within the rotor forging; and
thenoff-center machining the rotor forging to produce a machined rotor so that the geometric centerline of the transition zone is approximately the geometric centerline of the machined rotor. - View Dependent Claims (13, 14, 15, 16, 17)
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18. A method for processing a rotor forging, the method comprising the steps of:
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casting an ingot to have at least first and second ingot regions axially aligned within the ingot, the first and second ingot regions being formed of different alloys that intermix during casting to define a transition zone between the first and second ingot regions, the transition zone having a composition that differs from and varies between the first and second ingot regions; forging the ingot to produce a rotor forging containing first and second forging regions and a transition zone therebetween corresponding to the first and second ingot regions and the transition zone of the ingot such that the first and second forging regions are formed of the different alloys and the transition zone of the rotor forging has a composition that differs from and varies between the first and second forging regions, the first and second forging regions and the transition zone therebetween being axially aligned along a geometric centerline of the rotor forging; ascertaining boundary points of the transition zone within the rotor forging to define a plurality of two-dimensional cross-sectional shapes of the transition zone by ultrasonically examining the rotor forging to produce a noise pattern corresponding to variations in metallurgical characteristics within the rotor forging attributable to changes in chemistry between the transition zone and the first and second rotor regions; using the plurality of two-dimensional cross-sectional shapes to produce a three-dimensional approximation of the shape of the transition zone within the rotor forging; using the three-dimensional approximation to establish a geometric centerline of the transition zone within the rotor forging; and
thenoff-center machining the rotor forging to produce a machined rotor so that the geometric centerline of the transition zone is approximately the geometric centerline of the machined rotor. - View Dependent Claims (19, 20)
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Specification