# Patent

## Title
Hot stretch straightening of high strength age hardened metallic form and straightened age hardened metallic form

## Abstract

A method for straightening an age hardened metallic form includes heating an age hardened metallic form comprising one of a titanium alloy, a nickel alloy, an aluminum alloy, and a ferrous alloy to a straightening temperature of at least 25° F. below the age hardening temperature, and applying an elongation tensile stress for a time sufficient to elongate and straighten the form. The elongation tensile stress is at least 20% of the yield stress and not equal to or greater than the yield stress at the straightening temperature. The straightened form deviates from straight by no greater than 0.125 inch over any 5 foot length or shorter length. The straightened form is cooled while simultaneously applying a cooling tensile stress that balances the thermal cooling stress in the metallic form to thereby maintain a deviation from straight of no greater than 0.125 inch over any 5 foot length or shorter length.

## Background
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority under 35 U.S.C. §120 as a continuation application of U.S. patent application Ser. No. 12/845,122, filed Jul. 28, 2010, now U.S. Pat. No. 8,499,605, entitled “Hot Stretch Straightening of High Strength Alpha/Beta Processed Titanium”, which is incorporated by reference herein in its entirety.


BACKGROUND OF THE TECHNOLOGY
1. Field of the Technology
The present disclosure is directed to methods for straightening high strength titanium alloys aged in the α+β phase field.
2. Description of the Background of the Technology
Titanium alloys typically exhibit a high strength-to-weight ratio, are corrosion resistant, and are resistant to creep at moderately high temperatures. For these reasons, titanium alloys are used in aerospace and aeronautic applications including, for example, landing gear members, engine frames and other critical structural parts. Titanium alloys also are used in jet engine parts such as rotors, compressor blades, hydraulic system parts, and nacelles.
In recent years, β-titanium alloys have gained increased interest and application in the aerospace industry. β-titanium alloys are capable of being processed to very high strengths while maintaining reasonable toughness and ductility properties. In addition, the low flow stress of β-titanium alloys at elevated temperatures can result in improved processing.
However, β-titanium alloys can be difficult to process in the α+β phase field because, for example, the alloys' β-transus temperatures are typically in the range of 1400° F. to 1600° F. (760° C. to 871.1° C.). In addition, fast cooling, such as water or air quenching, is required after α+β solution treating and aging in order to achieve the desired mechanical properties of the product. A straight α+β solution treated and aged β-titanium alloy bar, for example, may warp and/or twist during quenching. (“Solution treated and aged” is referred to at times herein as “STA”.) In addition, the low aging temperatures that must be used for the β-titanium alloys, e.g., 890° F. to 950° F. (477° C. to 510° C.), severely limit the temperatures that can be used for subsequent straightening. Final straightening must occur below the aging temperature to prevent significant changes in mechanical properties during straightening operations.
For α+β titanium alloys, such as, for example, Ti-6Al-4V alloy, in long product or bar form, expensive vertical solution heat treating and aging processes are conventionally employed to minimize distortion. A typical example of the prior art STA processing includes suspending a long part, such as a bar, in a vertical furnace, solution treating the bar at a temperature in the α+β phase field, and aging the bar at a lower temperature in the α+β phase field. After fast quenching, e.g., water quenching, it may be possible to straighten the bar at temperatures lower than the aging temperature. Suspended in a vertical orientation, the stresses in the rod are more radial in nature and result in less distortion. An STA processed Ti-6Al-4V alloy (UNS R56400) bar can then be straightened by heating to a temperature below the aging temperature in a gas furnace, for example, and then straightened using a 2-plane, 7-plane, or other, straightener known to a person of ordinary skill. However, vertical heat treatment and water quenching operations are expensive and the capabilities are not found in all titanium alloy manufacturers
Because of the high room temperature strength of solution treated and aged β-titanium alloys, conventional straightening methods, such as vertical heat treating, are not effective for straightening long product, such as bar. After aging between 800° F. to 900° F. (427° C. to 482° C.), for example, STA metastable β-titanium Ti-15Mo alloy (UNS R58150) can have an ultimate tensile strength of 200 ksi (1379 MPa) at room temperature. Therefore, STA Ti-15Mo alloy does not lend itself to traditional straightening methods because the available straightening temperatures that would not affect mechanical properties are low enough that a bar composed of the alloy could shatter as straightening forces are applied.
Accordingly, a straightening process for solution treated and aged metals and metal alloys that does not significantly affect the strength of the aged metal or metal alloy is desirable.
SUMMARY
According to one aspect of the present disclosure, a non-limiting embodiment of a method for straightening an age hardened metallic form selected from one of a metal and a metal alloy includes heating an age hardened metallic form to a straightening temperature. In certain embodiments, the straightening temperature is in a straightening temperature range from 0.3 of the melting temperature in kelvin (0.3 Tm) of the age hardened metallic form to at least 25° F. (13.9° C.) below an aging temperature used to harden the age hardened metallic form. An elongation tensile stress is applied to the age hardened metallic form for a time sufficient to elongate and straighten the age hardened metallic form to provide a straightened age hardened metallic form. The straightened age hardened metallic form deviates from straight by no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length. The straightened age hardened metallic form is cooled while simultaneously applying a cooling tensile stress to the straightened age hardened metallic form that is sufficient to balance the thermal cooling stresses in the alloy and maintain a deviation from straight of no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened age hardened metallic form.
A method for straightening a solution treated and aged titanium alloy form includes heating a solution treated and aged titanium alloy form to a straightening temperature. The straightening temperature comprises a straightening temperature in the α+β phase field of the solution treated and aged titanium alloy form. In certain embodiments, the straightening temperature range is 1100° F. (611.1° C.) below a beta transus temperature of the solution treated and aged titanium alloy form to 25° F. (13.9° C.) below the age hardening temperature of the solution treated and aged titanium alloy form. An elongation tensile stress is applied to the solution treated and aged titanium alloy form for a time sufficient to elongate and straighten the solution treated and aged titanium alloy form to form a straightened solution treated and aged titanium alloy form. The straightened solution treated and aged titanium alloy form deviates from straight by no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length. The straightened solution treated and aged titanium alloy form is cooled while simultaneously applying a cooling tensile stress to the straightened solution treated and aged titanium alloy form. The cooling tensile stress is sufficient to balance a thermal cooling stress in the straightened solution treated and aged titanium alloy form and maintain a deviation from straight of no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened solution treated and aged titanium alloy form.



BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of methods described herein may be better understood by reference to the accompanying drawings in which:
FIG. 1 is a flow diagram of a non-limiting embodiment of a hot stretch straightening method for titanium alloy forms according to the present disclosure;
FIG. 2 is a schematic representation for measuring deviation from straight of metallic bar material;
FIG. 3 is a flow diagram of a non-limiting embodiment of a hot stretch straightening method for metallic product forms according to the present disclosure;
FIG. 4 is a photograph of solution treated and aged bars of Ti-10V-2Fe-3Al alloy;
FIG. 5 is a temperature versus time chart for straightening Serial #1 bar of the non-limiting example of Example 7;
FIG. 6 is a temperature versus time chart for straightening Serial #2 bar of the non-limiting example of Example 7;
FIG. 7 is a photograph of solution treated and aged bars of Ti-10V-2Fe-3Al alloy after hot stretch straightening according to a non-limiting embodiment of this disclosure;
FIG. 8 includes micrographs of microstructures of the hot stretch straightened bars of non-limiting Example 7; and
FIG. 9 includes micrographs of non-straightened solution treated and aged control bars of Example 9.



The reader will appreciate the foregoing details, as well as others, upon considering the following detailed description of certain non-limiting embodiments of methods according to the present disclosure.
DETAILED DESCRIPTION OF CERTAIN NON-LIMITING EMBODIMENTS
In the present description of non-limiting embodiments, other than in the operating examples or where otherwise indicated, all numbers expressing quantities or characteristics are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, any numerical parameters set forth in the following description are approximations that may vary depending on the desired properties one seeks to obtain in the methods according to the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
Any patent, publication, or other disclosure material that is said to be incorporated, in whole or in part, by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.
Referring now to the flow diagram of FIG. 1, a non-limiting embodiment of a hot stretch straightening method 10 for straightening a solution treated and aged titanium alloy form according to the present disclosure comprises heating 12 a solution treated and aged titanium alloy form to a straightening temperature. In a non-limiting embodiment, the straightening temperature is a temperature within the α+β phase field. In another non-limiting embodiment, the straightening temperature is in a straightening temperature range from about 1100° F. (611.1° C.) below the beta transus temperature of the titanium alloy to about 25° below the age hardening temperature of the solution treated and aged alloy form.
As used herein, “solution treated and aged” (STA) refers to a heat treating process for titanium alloys that includes solution treating a titanium alloy at a solution treating temperature in the two-phase region, i.e., in the α+β phase field of the titanium alloy. In a non-limiting embodiment, the solution treating temperature is in a range from about 50° F. (27.8° C.) below the β-transus temperature of the titanium alloy to about 200° F. (111.1° C.) below the β-transus temperature of the titanium alloy. In another non-limiting embodiment, a solution treatment time ranges from 30 minutes to 2 hours. It is recognized that in certain non-limiting embodiments, the solution treatment time may be shorter than 30 minutes or longer than 2 hours and is generally dependent upon the size and cross-section of the titanium alloy form. This two-phase region solution treatment dissolves much of the α-phase present in the titanium alloy, but leaves some α-phase remaining, which pins grain growth to some extent. Upon completion of the solution treatment, the titanium alloy is water quenched so that a significant portion of alloying elements is retained in the β-phase.
The solution treated titanium alloy is then aged at an aging temperature, also referred to herein as an age hardening temperature, in the two-phase field, ranging from 400° F. (222.2° C.) below the solution treating temperature to 900° F. (500° C.) below the solution treating temperature for an aging time sufficient to precipitate fine grain α-phase. In a non-limiting embodiment, the aging time may range from 30 minutes to 8 hours. It is recognized that in certain non-limiting embodiments, the aging time may be shorter than 30 minutes or longer than 8 hours longer and is generally dependent upon the size and cross-section of the titanium alloy form. The STA process produces titanium alloys exhibiting high yield strength and high ultimate tensile strength. The general techniques used in STA processing an alloy are known to practitioners of ordinary skill in the art and, therefore, are not further elaborated herein.
Referring again to FIG. 1, after heating 12, an elongation tensile stress is applied 14 to the STA titanium alloy form for a time sufficient to elongate and straighten the STA titanium alloy form and provide a straightened STA titanium alloy form. In a non-limiting embodiment, the elongation tensile stress is at least about 20% of the yield stress of the STA titanium alloy form at the straightening temperature and not equivalent to or greater than the yield stress of the STA titanium alloy form at the straightening temperature. In a non-limiting embodiment, the applied elongation tensile stress may be increased during the straightening step in order to maintain elongation. In a non-limiting embodiment, the elongation tensile stress is increased by a factor of 2 during elongation. In a non-limiting embodiment, the STA titanium alloy product form comprises Ti-10V-2Fe-3Al alloy (UNS 56410), which has a yield strength of about 60 ksi at 900° F. (482.2° C.), and the applied elongation stress is about 12.7 ksi at 900° F. at the beginning of straightening and about 25.5 ksi at the end of the elongation step.
In another non-limiting embodiment, after applying the elongation tensile stress 14, the straightened STA titanium alloy form deviates from straight by no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length.
It is recognized that it is within the scope of non-limiting embodiments of this disclosure that the elongation tensile stress could be applied while allowing the form to cool. It will be understood, however, that because stress is a function of temperature, as the temperature decreases the required elongation stress would have to be increased to continue to elongate and straighten the form.
In a non-limiting embodiment, when the STA titanium alloy form is sufficiently straightened, the STA titanium alloy form is cooled 16 while simultaneously applying a cooling tensile stress 18 to the straightened solution treated and aged titanium alloy form. In a non-limiting embodiment, the cooling tensile stress is sufficient to balance a thermal cooling stress in the straightened STA titanium alloy form so that the STA titanium alloy form does not warp, curve, or otherwise distort during cooling. In a non-limiting embodiment, the cooling stress is equivalent to the elongation stress. It is recognized that because the temperature of the product form decreases during cooling, applying a cooling tensile stress that is equivalent to the elongation tensile stress will not cause further elongation of the product form, but does serve to prevent cooling stresses in the product form from warping the product form and maintains the deviation from straight that was established in the elongation step.
In a non-limiting embodiment, the cooling tensile stress is sufficient to maintain a deviation from straight of no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened STA titanium alloy form.
In a non-limiting embodiment, the elongation tensile stress and the cooling tensile stress are sufficient to enable creep forming of the STA titanium alloy form. Creep forming takes place in the normally elastic regime. While not wanting to be bound by any particular theory, it is believed that the applied stress in the normally elastic regime at the straightening temperature allows grain boundary sliding and dynamic dislocation recovery that results in straightening of the product form. After cooling and compensating for the thermal cooling stresses by maintaining a cooling tensile stress on the product form, the moved dislocations and grain boundaries assume the new elastic state of the STA titanium alloy product form.
Referring to FIG. 2, in a method 20 for determining the deviation from straight of a product form, such as, for example, a bar 22, the bar 22 is lined up next to a straight edge 24. The curvature of the bar 22 is measured at curved or twisted locations on the bar with a device used to measure length, such as a tape measure, as the distance the bar curves away from the straight edge 24. The distance of each twist or curve from the straight edge is measured along a prescribed length of the bar 28 to determine the maximum deviation from straight (26 in FIG. 2), i.e., the maximum distance of the bar 22 from the straight edge 24 within the prescribed length of the bar 22. The same technique may be used to quantify deviation from straight for other product forms.
In another non-limiting embodiment, after applying the elongation tensile stress according to the present disclosure, the straightened STA titanium alloy form deviates from straight by no greater than 0.094 inch (2.388 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened STA titanium alloy form. In yet another non-limiting embodiment, after cooling while applying the cooling tensile stress according to the present disclosure, the straightened STA titanium alloy form deviates from straight by no greater than 0.094 inch (2.388 mm) over any 5 foot length (152.4 cm) or short length of the straightened STA titanium alloy form. In still another non-limiting embodiment, after applying the elongation tensile stress according to the present disclosure, the straightened STA titanium alloy form deviates from straight by no greater than 0.25 inch (6.35 mm) over any 10 foot length (304.8 cm) or shorter length of the straightened STA titanium alloy form. In still another non-limiting embodiment, after cooling while applying the cooling tensile stress according to the present disclosure, the straightened STA titanium alloy form deviates from straight by no greater than 0.25 inch (6.35 mm) over any 10 foot length (304.8 cm) or shorter length of the straightened STA titanium alloy form.
In order to uniformly apply the elongation and cooling tensile stresses, in a non-limiting embodiment according to the present disclosure, the STA titanium alloy form must be capable of being gripped securely across the entire cross-section of the STA titanium alloy form. In a non-limiting embodiment, the shape of the STA titanium alloy form can be the shape of any mill product for which adequate grips can be fabricated to apply a tensile stress according to the method of the present disclosure. A “mill product” as used herein is any metallic, i.e., metal or metal alloy, product of a mill that is subsequently used as-fabricated or is further fabricated into an intermediate or finished product. In a non-limiting embodiment an STA titanium alloy form comprises one of a billet, a bloom, a round bar, a square bar, an extrusion, a tube, a pipe, a slab, a sheet, and a plate. Grips and machinery for applying the elongating and cooling tensile stresses according to the present disclosure are available from, for example, Cyril Bath Co., Monroe, N.C., USA.
A surprising aspect of this disclosure is the ability to hot stretch straighten STA titanium alloy forms without significantly reducing the tensile strengths of the STA titanium alloy forms. For example, in a non-limiting embodiment, the average yield strength and average ultimate tensile strength of the hot stretch straightened STA titanium alloy form according to non-limiting methods of this disclosure are reduced by no more than 5 percent from values before hot stretch straightening. The largest change in properties produced by hot stretch straightening that was observed was in percent elongation. For example, in a non-limiting embodiment according to the present disclosure, the average value for percent elongation of a titanium alloy form exhibited an absolute reduction of about 2.5% after hot stretch straightening. Without intending to be bound by any theory of operation, it is believed that a decrease in percent elongation may occur due to the elongation of the STA titanium alloy form that occurs during non-limiting embodiments of hot stretch straightening according to this disclosure. For example, in a non-limiting embodiment, after hot stretch straightening the present disclosure, a straightened STA titanium alloy form may be elongated by about 1.0% to about 1.6% versus the length of the STA titanium alloy form prior to hot stretch straightening.
Heating the STA titanium alloy form to a straightening temperature according to the present disclosure may employ any single or combination of forms of heating capable of maintaining the straightening temperature of the bar, such as, but not limited to, heating in a box furnace, radiant heating, and induction heating the form. The temperature of the form must be monitored to ensure that the temperature of the form remains at least 25° F. (13.9° C.) below the aging temperature used during the STA process. In non-limiting embodiments, the temperature of the form is monitored using thermocouples or infrared sensors. However, other means of heating and monitoring the temperature known to persons of ordinary skill in the art are within the scope of this disclosure.
In one non-limiting embodiment, the straightening temperature of the STA titanium alloy form should be relatively uniform throughout and should not vary from location to location by more than 100° F. (55.6° C.). The temperature at any location of the STA titanium alloy form preferably does not increase above the STA aging temperature, because the mechanical properties, including, but not limited to the yield strength and ultimate tensile strength, could be detrimentally affected.
The rate of heating the STA titanium alloy form to the straightening temperature is not critical, with the precaution that faster heating rates could result in overrun of the straightening temperature and result in loss of mechanical properties. By taking precautions not to overrun the target straightening temperature, or not to overrun a temperature at least 25° F. (13.9° C.) below the STA aging temperature, faster heating rates can result in shorter straightening cycle times between parts, and improved productivity. In a non-limiting embodiment, heating to the straightening temperature comprises heating at a heating rate from 500° F./min (277.8° C./min) to 1000° F./min (555.6° C./min).
Any localized area of the STA titanium alloy form preferably should not reach a temperature equal to or greater than the STA aging temperature. In a non-limiting embodiment, the temperature of the form should always be at least 25° F. (13.9° C.) below the STA aging temperature. In a non-limiting embodiment, the STA aging temperature (also variously referred to herein as the age hardening temperature, the age hardening temperature in the α+β phase field, and the aging temperature) may be in a range of 500° F. (277.8° C.) below the β-transus temperature of the titanium alloy to 900° F. (500° C.) below the β-transus temperature of the titanium alloy. In other non-limiting embodiments, the straightening temperature is in a straightening temperature range of 50° F. (27.8° C.) below the age hardening temperature of the STA titanium alloy form to 200° F. (111.1° C.) below the age hardening temperature of the STA titanium alloy form, or is in a straightening temperature range of 25° F. (13.9° C.) below the age hardening temperature to 300° F. (166.7° C.) below the age hardening temperature.
A non-limiting embodiment of a method according to the present disclosure comprises cooling the straightened STA titanium alloy form to a final temperature at which point the cooling tensile stress can be removed without changing the deviation from straight of the straightened STA titanium alloy form. In a non-limiting embodiment, cooling comprises cooling to a final temperature no greater than 250° F. (121.1° C.). The ability to cool to a temperature higher than room temperature while being able to relieve the cooling tensile stress without deviation in straightness of the STA titanium alloy form allows for shorter straightening cycle times between parts and improved productivity. In another non-limiting embodiment, cooling comprises cooling to room temperature, which is defined herein as about 64° F. (18° C.) to about 77° F. (25° C.).
As will be seen, an aspect of this disclosure is that certain non-limiting embodiments of hot stretch straightening disclosed herein can be used on substantially any metallic form comprising many, if not all, metals and metal alloys, including, but not limited to, metals and metal alloys that are conventionally considered to be hard to straighten. Surprisingly, non-limiting embodiments of the hot stretch straightening method disclosed herein were effective on titanium alloys that are conventionally considered to be hard to straighten. In a non-limiting embodiment within the scope of this disclosure, the titanium alloy form comprises a near α-titanium alloy. In a non-limiting embodiment, the titanium alloy form comprises at least one of Ti-8Al-1Mo-1V alloy (UNS 54810) and Ti-6Al-2Sn-4Zr-2Mo alloy (UNS R54620).
In a non-limiting embodiment within the scope of this disclosure, the titanium alloy form comprises an α+β-titanium alloy. In another non-limiting embodiment, the titanium alloy form comprises at least one of Ti-6Al-4V alloy (UNS R56400), Ti-6Al-4V ELI alloy (UNSR56401), Ti-6Al-2Sn-4Zr-6Mo alloy (UNS R56260), Ti-5Al-2Sn-2Zr-4Mo-4Cr alloy (UNS R58650), and Ti-6Al-6V-2Sn alloy (UNS R56620).
In still another non-limiting embodiment, the titanium alloy form comprises a β-titanium alloy. A “β-titanium alloy”, as used herein, includes, but is not limited to, near β-titanium alloys and metastable β-titanium alloys. In a non-limiting embodiment, the titanium alloy form comprises one of Ti-10V-2Fe-3Al alloy (UNS 56410), Ti-5Al-5V-5Mo-3Cr alloy (UNS unassigned), Ti-5Al-2Sn-4Mo-2Zr-4Cr alloy (UNS R58650), and Ti-15Mo alloy (UNS R58150). In a specific non-limiting embodiment, the titanium alloy form is a Ti-10V-2Fe-3Al alloy (UNS 56410) form.
It is noted that with certain (3-titanium alloys, for example, Ti-10V-2Fe-3Al alloy, it is not possible to straighten STA forms of these alloys to the tolerances disclosed herein using conventional straightening processes, while also maintaining the desired mechanical properties of the alloy. For β-titanium alloys, the β transus temperature is inherently lower than commercially pure titanium. Therefore, the STA aging temperature also must be lower. In addition, STA β-titanium alloys such as, but not limited to, Ti-10V-2Fe-3Al alloy can exhibit ultimate tensile strengths higher than 200 ksi (1379 MPa). When attempting to straighten STA β-titanium alloy bars having such high strengths using conventional stretching methods, such as using a two-plane straightener, at temperatures no greater than 25° F. (13.9° C.) below the STA aging temperature, the bars exhibit a strong tendency to shatter. Surprisingly, it has been discovered that these high strength STA β-titanium alloys can be straightened to the tolerances disclosed herein using non-limiting hot stretch straightening method embodiments according to this disclosure without fracturing and with only an average loss of yield and ultimate tensile strengths of about 5%.
While the discussion hereinabove is concerned primarily with straightened titanium alloy forms and methods of straightening STA titanium alloy forms, non-limiting embodiments of hot stretch straightening disclosed herein may be used successfully on virtually any age hardened metallic product form, i.e., a metallic product comprising any metal or metal alloy.
Referring to FIG. 3, in a non-limiting embodiment according to the present disclosure, a method 30 for straightening a solution treated and age hardened metallic form including one of a metal and a metal alloy comprises heating 32 a solution treated and age hardened metallic form to a straightening temperature in a straightening temperature range from 0.3 of a melting temperature in kelvin (0.3 Tm) of the age hardened metallic form to a temperature of at least 25° F. (13.9° C.) below the aging temperature used to harden the age hardened metallic form.
A non-limiting embodiment according to the present disclosure comprises applying 34 an elongation tensile stress to a solution treated and age hardened metallic form for a time sufficient to elongate and straighten the age hardened metallic form to provide a straightened age hardened metallic form. In a non-limiting embodiment, the elongation tensile stress is at least about 20% of the yield stress of the age hardened metallic form at the straightening temperature and is not equivalent to or greater than the yield stress of the age hardened metallic form at the straightening temperature. In a non-limiting embodiment, the applied elongation tensile stress may be increased during the straightening step in order to maintain elongation. In a non-limiting embodiment, the elongation tensile stress is increased by a factor of 2 during elongation. In a non-limiting embodiment, the straightened age hardened metallic form deviates from straight by no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length. In a non-limiting embodiment, the straightened age hardened metallic form deviates from straight by no greater than 0.094 inch (2.388 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened age hardened metallic form. In still another non-limiting embodiment, the straightened age hardened metallic form deviates from straight by no greater than 0.25 inch (6.35 mm) over any 10 foot (304.8 cm) length of the straightened age hardened metallic form.
A non-limiting embodiment according to the present disclosure comprises cooling 36 the straightened age hardened metallic form while simultaneously applying 38 a cooling tensile stress to the straightened age hardened metallic form. In another non-limiting embodiment, the cooling tensile stress is sufficient to balance a thermal cooling stress in the straightened age hardened metallic form so that the straightened age hardened metallic form does not warp, curve, or otherwise distort during cooling. In a non-limiting embodiment, the cooling stress is equivalent to the elongation stress. It is recognized that because the temperature of the product form decreases during cooling, applying a cooling tensile stress that is equivalent to the elongation tensile stress will not cause further elongation of the product form, but does serve to prevent cooling stresses in the product form from warping the product form and maintains the deviation from straight that was established in the elongation step. In another non-limiting embodiment, the cooling tensile stress is sufficient to balance a thermal cooling stress in the alloy so that the age hardened metallic form does not warp, curve, or otherwise distort during cooling. In still another non-limiting embodiment, the cooling tensile stress is sufficient to balance a thermal cooling stress in the alloy so that the age hardened metallic form maintains a deviation from straight of no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened age hardened metallic form. In yet another non-limiting embodiment, the cooling stress is sufficient to balance a thermal cooling stress in the alloy so that the age hardened metallic form maintains a deviation from straight of no greater than 0.094 inch (2.388 mm) over any 5 foot length (152.4 cm) or shorter length. In yet another non-limiting embodiment, the cooling stress is sufficient to balance a thermal cooling stress in the alloy so that the age hardened metallic form maintains a deviation from straight of no greater than 0.25 inch (6.35 mm) over any 10 foot (304.8 cm) length of the straightened age hardened metallic form.
In various non-limiting embodiments according to the present disclosure, the solution treated and age hardened metallic form comprises one of a titanium alloy, a nickel alloy, an aluminum alloy, and a ferrous alloy. Also, in certain non-limiting embodiments according to the present disclosure, the solution treated and age hardened metallic form is selected from a billet, a bloom, a round bar, a square bar, an extrusion, a tube, a pipe, a slab, a sheet, and a plate.
In a non-limiting embodiment according to the present disclosure, the straightening temperature is in a range from 200° F. (111.1° C.) below the age hardening temperature used to harden the age hardened metallic form up to 25° F. (13.9° C.) below the age hardening temperature used to harden the age hardened metallic form.
The examples that follow are intended to further describe certain non-limiting embodiments, without restricting the scope of the present invention. Persons having ordinary skill in the art will appreciate that variations of the following examples are possible within the scope of the invention, which is defined solely by the claims.
EXAMPLE 1
In this comparative example, several 10 foot long bars of Ti-10V-2Fe-3Al alloy were fabricated and processed using several permutations of solution treating, aging, and conventional straightening in an attempt to identify a robust process to straighten the bars. The bars ranged in diameter from 0.5 inch to 3 inches (1.27 cm to 7.62 cm). The bars were solution treated at temperatures from 1375° F.). (746.1° to 1475° F. (801.7° C.). The bars were then aged at aging temperature ranging from 900° F. (482.2° C.) to 1000° F. (537.8° C.). Processes evaluated for straightening included: (a) vertical solution treatment and 2-plane straightening below the aging temperature; (b) vertical solution heat treatment followed by 2-plane straightening at 1400° F. (760° C.), aging, and 2-plane straightening at 25° F. (13.9° F.) below the aging temperature; (c) straightening at 1400° F. (760° C.) followed by vertical solution treatment and aging, and 2-plane straightening at 25° F. (13.9° C.) below the aging temperature; (d) high temperature solution heat treating followed by 2-plane straightening at 1400° F. (760° C.), vertical solution treating and aging, and 2-plane straightening at 25° F. (13.9° C.) below the aging temperature; and (e) mill annealing followed by 2-plane straightening at 1100° F. (593.3° C.), vertical solution heat treating, and 2-plane straightening at 25° F. (13.9° C.) below the aging temperature.
The processed bars were visually inspected for straightness and were graded as either passing or failing. It was observed that the process labeled (e) was the most successful. All attempts using vertical STA heat treatments, however, had no more than a 50% passing rate.
EXAMPLE 2
Two 1.875 inch (47.625 mm) diameter, 10 foot (3.048 m) bars of Ti-10V-2Fe-3Al alloy were used for this example. The bars were rolled at a temperature in the α+β phase field from rotary forged re-roll that was produced from upset and single recrystallized billet. Elevated temperature tensile tests at 900° F. (482.2° C.) were performed to determine the maximum diameter of bar that could be straightened with the available equipment. The elevated temperature tensile tests indicated that a 1.0 inch (2.54 cm) diameter bar was within the equipment limitations. The bars were peeled to 1.0 inch (2.54 cm) diameter bars. The bars were then solution treated at 1460° F. (793.3° C.) for 2 hours and water quenched. The bars were aged for 8 hours at 940° F. (504.4° C.). The straightness of the bars was measured to deviate approximately 2 inch (5.08 cm) from straight with some twist and wave. The STA bars exhibited two different types of bow. The first bar (Serial #1) was observed to be relatively straight at the ends and had a gentle bow to the middle of approximately 2.1 inch (5.334 cm) from straight. The second bar (Serial #2) was fairly straight near the middle, but had kinks near the ends. The maximum deviation from straight was around 2.1 inch (5.334 cm). The surface finish of the bars in the as-quenched condition exhibited a fairly uniform oxidized surface. FIG. 4 is a representative photograph of the bars after solution treating and aging.
EXAMPLE 3
The solution treated and aged bars of Example 2 were hot stretch straightened according to a non-limiting embodiment of this disclosure. The temperature feedback for the control of bar temperature was via a thermocouple located at the middle of the part. However, to address inherent difficulties with thermocouple attachment, two additional thermocouples were welded to the parts near their ends.
The first bar experienced a failed main control thermocouple, resulting in oscillations during the heat ramp. This, along with another control anomaly, led to the part exceeding the desired temperature of 900° F. (482.2° C.). The high temperature achieved was approximately 1025° F. (551.7° C.) for less than 2 minutes. The first bar was re-instrumented with another thermocouple, and a similar overshoot occurred due to an error in the software control program from the previous run. The first bar was heated with the maximum power permitted, which can heat a bar of the size used in this example from room temperature to 1000° F. (537.8° C.) in approximately 2 minutes.
The program was reset and the first bar straightening program was allowed to proceed. The highest temperature recorded was 944° F. (506.7° C.) by thermocouple number 2 (TC#2), which was positioned near one end of the bar. It is believed that TC#2 experienced a mild hot junction failure when under power. During this cycle, thermocouple number 0 (TC#0), positioned in the center of the bar, recorded a maximum temperature of 908° F. (486.7° C.). During the straightening, thermocouple number 1 (TC#1), positioned near the opposite end of the bar from TC#2, fell off the bar and discontinued reading the bar temperature. The temperature graph for this final heat cycle on bar Serial #1 is shown in FIG. 5. The cycle time for the first bar (Serial #1) was 50 minutes. The bar was cooled to 250° F. (121.1° C.) while maintaining the tonnage on the bar that was applied at the end of the elongation step.
The first bar was elongated 0.5 inch (1.27 cm) over the span of 3 minutes. The tonnage during that phase was increased from 5 tons (44.5 kN) initially to 10 tons (89.0 kN) after completion. Because the bar has a 1 inch (2.54 cm) diameter, these tonnages translate to tensile stresses of 12.7 ksi (87.6 MPa) and 25.5 ksi (175.8 MPa). The part had also experienced elongation in the previous heat cycles that were discontinued due to temperature control failure. The total measured elongation after straightening was 1.31 inch (3.327 cm).
The second bar (Serial #2) was carefully cleaned near the thermocouple attachment points and the thermocouples were attached and inspected for obvious defects. The second bar was heated to a target set point of 900° F. (482.2° C.). TC#1 recorded a temperature of 973° F. (522.8° C.), while TC#0 and TC#2 recorded temperatures of only 909° F. (487.2° C.) and 911° F. (488.3° C.), respectively. TC#1 tracked well with the other two thermocouples until around 700° F. (371.1° C.), at which point some deviation was observed, as seen in FIG. 6. Once again, the attachment of the thermocouple was suspected to be the source of the deviation. The total cycle time for this part was 45 minutes. The second bar (Serial #2) was hot stretched as described for the first bar (Serial #1).
The hot stretch straightened bars (Serial #1 and Serial #2) are shown in the photograph of FIG. 7. The bars had a maximum deviation from straight of 0.094 inch (2.387 mm) over any 5 foot (1.524 m) length. Serial #1 bar was lengthened by 1.313 inch (3.335 cm), and Serial #2 bar was lengthened by 2.063 inch (5.240 cm) during hot stretch straightening.
EXAMPLE 4
The chemistries of bars Serial #1 and Serial #2 after hot stretch straightening according to Example 3 were compared with the chemistry of the 1.875 inch (47.625 mm) bars of Example 2. The bars of Example 3 were produced from the same heat as the straightened bars Serial #1 and Serial #2. The results of the chemical analysis are presented in Table 1.
















TABLE 1





MOT
Size
Al
C
Fe
H
N
O
Ti
V







69550C
1.875′′RD
3.089
0.008
1.917
0.004
0.006
0.108
85.275
9.654


69550C
1.875′′RD
3.070
0.007
1.905
0.005
0.004
0.104
85.346
9.616


69550C
1.875′′RD
3.090
0.010
1.912
0.004
0.004
0.102
85.288
9.647


69550C
1.875′′RD
3.088
0.009
1.926
0.005
0.004
0.106
85.291
9.635


69550C
1.875′′RD
3.058
0.007
1.913
0.006
0.004
0.104
85.350
9.610



AVG
3.079
0.008
1.915
0.005
0.004
0.105
85.310
9.632


92993F
1′′RD
3.098
0.006
1.902
0.005
0.002
0.112
85.306
9.608


92993F
1′′RD
3.060
0.006
1.899
0.004
0.002
0.104
85.368
9.598



AVG
3.079
0.006
1.901
0.004
0.002
0.108
85.337
9.603









No change in chemistry was observed to have occurred from hot stretch straightening according to the non-limiting embodiment of Example 3.

EXAMPLE 5
The mechanical properties of the hot stretch straightened bars Serial #1 and Serial #2 were compared with control bars that were solution treated and aged, 2-plane straightened at 1400° F., and bumped. Bumping is a process in which a small amount of force is exerted with a die on a bar to work out small amounts of curvature over long lengths of the bar. The control bars consisted of Ti-10V-2Fe-3Al alloy and were 1.772 inch (4.501 cm) in diameter. The control bars were α+β solution treated at 1460° F. (793.3° C.) for 2 hours and water quenched. The control bars were aged at 950° F. (510° C.) for 8 hours and air quenched. The tensile properties and fracture toughness of the control bars and the hot stretch straightened bars were measured, and the results are presented in Table 2.














TABLE 2












K1c



DIASIZE

YLD
UTS
ELG
RA
(ksi


MOT
(inch)
HEAT
(ksi)
(ksi)
(%)
(%)
in1/2)















Hot Straightened and Bumped Bars














69548E
1.772RD
H94H
170.13
183.04
12.14
42.91
44.10


69548E
1.772RD
H94H
172.01
183.99
11.43
41.59
45.90


69548E
1.772RD
H94H
173.09
183.48
10.71
41.76
48.90


69548E
1.772RD
H94H
171.53
182.76
12.14
46.96
47.30


69548E
1.772RD
H94H
170.48
182.97
11.43
38.53
46.60


69548E
1.772RD
H94H
169.51
183.84
11.43
40.20
46.60


69548E
1.772RD
H94H
171.38
183.02
12.86
47.69
46.00


69548E
1.772RD
H94H
171.21
183.31
12.14
44.40
47.90




AVG
171.17
183.30
11.79
43.00
46.66







Hot Stretch Straightened Bars














92993F
1RD
H94H
172.01
182.68
8.57
29.34
47.50


92993F
1RD
H94H
170.78
180.91
10.00
36.85
49.40




AVG
171.39
181.79
9.29
33.10
48.45













Target Mean

167
176
6
NA
39


Minimums

158
170
6
NA
40









All properties of the hot stretch straightened bars meet the target and minimum requirements. The hot stretch straightened bars, Serial #1 and Serial #2, have slightly lower ductility and reduction in area (RA) values, which is most likely a result of the elongation that occurs during straightening. However, the tensile strengths after hot stretch straightening appear to be comparable to the un-straightened control bars.
EXAMPLE 6
The longitudinal microstructures of the hot stretch straightened bars, Serial #1 and Serial #2, were compared with the longitudinal microstructures of the un-straightened control bars of Example 5. Micrographs of microstructures of the hot stretch straightened bars of Example 3 are presented in FIG. 8. The micrographs were taken from two different locations on the same sample. Micrographs of the microstructures of the un-straightened control bars of Example 5 are presented in FIG. 9. It is observed that the microstructures are very similar.
The present disclosure has been written with reference to various exemplary, illustrative, and non-limiting embodiments. However, it will be recognized by persons having ordinary skill in the art that various substitutions, modifications, or combinations of any of the disclosed embodiments (or portions thereof) may be made without departing from the scope of the invention as defined solely by the claims. Thus, it is contemplated and understood that the present disclosure embraces additional embodiments not expressly set forth herein. Such embodiments may be obtained, for example, by combining and/or modifying any of the disclosed steps, ingredients, constituents, components, elements, features, aspects, and the like, of the embodiments described herein. Thus, this disclosure is not limited by the description of the various exemplary, illustrative, and non-limiting embodiments, but rather solely by the claims. In this manner, it will be understood that the claims may be amended during prosecution of the present patent application to add features to the claimed invention as variously described herein.

## Claims

1. A method for straightening an age hardened metallic form selected from one of a metal and a metal alloy, comprising:
heating an age hardened metallic form to a straightening temperature,
wherein the straightening temperature is in a straightening temperature range from 0.3 of a melting temperature in kelvin (0.3 Tm) of the age hardened metallic form to 25° F. (13.9° C.) below an aging temperature used to harden the age hardened metallic form;

applying an elongation tensile stress to the age hardened metallic form for a time sufficient to elongate and straighten the age hardened metallic form to provide a straightened age hardened metallic form,
wherein the straightened age hardened metallic form deviates from straight by no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length; and

cooling the straightened age hardened metallic form while simultaneously applying a cooling tensile stress to the straightened age hardened metallic form,
wherein the cooling tensile stress is sufficient to balance a thermal cooling stress in the alloy and maintain a deviation from straight of no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened age hardened metallic form.

2. The method of claim 1, wherein the elongation stress is at least 20% of a yield stress and not equal to or greater than the yield stress of the age hardened metallic form at the straightening temperature.

3. The method of claim 1, wherein the straightened age hardened metallic form deviates from straight by no greater than 0.094 inch (2.388 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened age hardened metallic form.

4. The method of claim 3, wherein the cooling stress is sufficient to balance a thermal cooling stress in the alloy and maintain a deviation from straight of no greater than 0.094 inch (2.388 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened age hardened metallic form.

5. The method of claim 1, wherein the straightened age hardened metallic form deviates from straight by no greater than 0.25 inch (6.35 mm) over any 10 foot (304.8 cm) length of the straightened age hardened metallic form.

6. The method of claim 1, wherein the age hardened metallic form comprises a material selected from the group consisting of a titanium alloy, a nickel alloy, an aluminum alloy, and a ferrous alloy.

7. The method of claim 1, wherein the age hardened metallic form is a form selected from the group consisting of a billet, a bloom, a round bar, a square bar, an extrusion, a tube, a pipe, a slab, a sheet, and a plate.

8. The method of claim 1, wherein the straightening temperature is in a range from 200° F. (111.1° C.) below the age hardening temperature used to harden the age hardened metallic form up to 25° F. (13.9° C.) below the age hardening temperature used to harden the age hardened metallic form.

9. A method for straightening an age hardened metallic form selected from one of a metal and a metal alloy, comprising:
heating an age hardened metallic form to a straightening temperature,
wherein the straightening temperature is in a straightening temperature range from 0.3 of a melting temperature in kelvin (0.3 Tm) of the age hardened metallic form to 25° F. (13.9° C.) below an aging temperature used to harden the age hardened metallic form;

applying an elongation tensile stress to the age hardened metallic form for a time sufficient to elongate and straighten the age hardened metallic form to provide a straightened age hardened metallic form,
wherein the elongation stress is at least 20% of a yield stress and not equal to or greater than the yield stress of the age hardened metallic form at the straightening temperature; and
wherein the straightened age hardened metallic form deviates from straight by no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length; and

cooling the straightened age hardened metallic form while simultaneously applying a cooling tensile stress to the straightened age hardened metallic form,
wherein the cooling tensile stress is sufficient to balance a thermal cooling stress in the alloy and maintain a deviation from straight of no greater than 0.125 inch (3.175 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened age hardened metallic form.

10. The method of claim 9, wherein the straightened age hardened metallic form deviates from straight by no greater than 0.094 inch (2.388 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened age hardened metallic form.

11. The method of claim 10, wherein the cooling stress is sufficient to balance a thermal cooling stress in the alloy and maintain a deviation from straight of no greater than 0.094 inch (2.388 mm) over any 5 foot length (152.4 cm) or shorter length of the straightened age hardened metallic form.

12. The method of claim 9, wherein the straightened age hardened metallic form deviates from straight by no greater than 0.25 inch (6.35 mm) over any 10 foot (304.8 cm) length of the straightened age hardened metallic form.

13. The method of claim 9, wherein the age hardened metallic form comprises a material selected from the group consisting of a titanium alloy, a nickel alloy, an aluminum alloy, and a ferrous alloy.

14. The method of claim 9, wherein the age hardened metallic form is a form selected from the group consisting of a billet, a bloom, a round bar, a square bar, an extrusion, a tube, a pipe, a slab, a sheet, and a plate.

15. The method of claim 9, wherein the straightening temperature is in a range from 200° F. (111.1° C.) below the age hardening temperature used to harden the age hardened metallic form up to 25° F. (13.9° C.) below the age hardening temperature used to harden the age hardened metallic form.