Patent ID: 9216453
Filing Date: 2015-12-22
Classification: B22F,C22C,F05D

Abstract:
1. A method of forming a dual microstructure component, the method comprising the steps of: consolidating a powder material comprising an alloy via HIP processing and/or extrusion to form a solid, cylindrical billet having an axial length from about 1 meter to about 3 meters, the billet having a first grain structure; inductively heating the solid, cylindrical billet at an inductive heat treat temperature above a gamma prime solvus temperature of the alloy and subjecting the solid, cylindrical billet to a subsolvus heat treat temperature that is below the gamma prime solvus temperature of the alloy in a range of about 3.5° C. to about 25° C. lower than the gamma prime solvus temperature of the alloy; waiting a period of time for the first grain structure in an outer portion of the solid, cylindrical billet to transform into a second grain structure that is coarser than the first grain structure, after the steps of inductively heating and subjecting the solid, cylindrical billet to the subsolvus heat treat temperature; slicing the solid, cylindrical billet into at least ten sections subsequent to the steps of inductively heating the billet and waiting a period of time; and machining a final shape into one or more of the at least ten sections to form the dual microstructure component, wherein the step of machining comprises forming a bore hole in the ten or more sections to form a turbine disk shape, and wherein the method omits isothermal forging of the at least ten sections.