Abstract: A method is taught for the isostatic forging of integrally bladed rotors, in which deformable hollow single crystal blades are protected from deformation during diffusion bonding to the disk by encapsulation in a ceramic protective shell. The ceramic shell serves to occupy the areas between the blades and the surrounding forging die set, so that during application of high temperatures and pressures, damage to the blades is prevented without the use of complex segmented die assemblies.

Abstract: A die package for forming a central disc structure having a plurality of integrally formed appendages extending therefrom includes a cylindrical array of appendage forming, abutting die segments which are prevented from tilting or moving in a circumferential direction by means of pins extending into slots formed along the parting lines between abutting die segments in the upper surfaces of the segments. In one embodiment, the pins extend upwardly from between opposed, parallel, radially and axially extending walls of each slot and fit tightly between said walls. The upper ends of the pins are secured to a rigid annular ring overlying the slots. The slots extend radially inwardly of the pins to allow the die segments to be moved radially outwardly after forging to release the forging from the die package.

Abstract: Apparatus for increasing the twist of blades of an integrally bladed rotor comprise a plurality of pairs of opposed, aligned blade formers, slideably disposed in guide channels on opposite sides of the blades to be twisted. The rotor and twisting apparatus is heated and the opposed formers are forced toward each other. The blade disposed between each pair of formers is sandwiched between the ends of the formers. The ends of the formers are specially shaped such that the blades are reshaped or twisted to the desired final contour.

Abstract: The present invention provides methods and apparatus improving the dimensional accuracy of forged components. Uniformity of like component details is sought and a specific object is to provide a die package for forming closely toleranced appendages integrally with a central disk structure from which the appendages extend. In one effective embodiment incorporating concepts of the present invention, the forging dies include a stationary die and a movable die comprising at least two separately movable elements which are mounted on a common axis with the stationary die. A plurality of arcuate die segments are adjacently placed in cylindrical array about the stationary and movable dies. The arcuate die segments form cavities of the inverse geometry of the appendages to be formed and in at least one embodiment are interlocked to prevent tilting of the segments in the die package.

Abstract: The present invention provides methods and apparatus improving the dimensional accuracy of forged components. Uniformity of like component details is sought and a specific object is to provide a die package for forming closely toleranced appendages integrally with a central disk structure from which the appendages extend.In one effective embodiment incorporating concepts of the present invention, the forging dies include a stationary die and a movable die comprising at least two separately movable elements which are mounted on a common axis with the stationary die. A plurality of arcuate die segments are adjacently placed in cylindrical array about the stationary and movable dies. The arcuate die segments form cavities of the inverse geometry of the appendages to be formed and in at least one embodiment are interlocked to prevent tilting of the segments in the die package.

Abstract: The present invention provides a technique for improving the dimensional accuracy of forged components. Uniformity of like component details is sought and a specific object is to provide a die package for forming closely toleranced appendages integrally with a central disk structure from which the appendages extend.In one effective embodiment incorporating concepts of the present invention, the forging dies include a stationary die 26 and a moveable die 28 which are mounted on a common axis and a plurality of arcuate die segments 30 which are adjacently placed in cylindrical array about the stationary and moveable dies. The arcuate die segments form cavities of the inverse geometry of the appendages to be formed and are interlocked to prevent tilting of the segments in the die package. A collar 40 extends from the stationary die to interlocking engagement with a channel 46 in the inwardly facing surface of each arcuate die segment.

Abstract: A rotor for a gas turbine engine has a wrought superalloy disk with ceramic blades. The rotor is formed by placing ceramic blades in a fixture with their ceramic blade roots extending inwardly and between the upper and lower rims of a disk or disk halves. The facing upper and lower circumferential rims are cut away to provide for the ceramic blade roots. Said disk or disk halves being of a wrought superalloy having a fine grain size microstructure which can be placed in a superplastic condition. A compliant layer material is placed between the ceramic blade roots and the rims of the disk, and the disk and compliant layer are then heated so as to place the disk in a superplastic condition and pressed into intimate contact with the ceramic blade root, and if disk halves are being used, they are bonded together at inner mating surfaces. The rotor is then heat treated to return the disk to its normal condition of high strength and hardness.

Abstract: Apparatus for converting particulate metallic matter into a billet or a forged article in which the material is fed in measured quantity from a hopper to a furnace for outgassing and other heat treatment and thence to a press in which the particulate material is compacted into a container or mold to form either a billet or forged article. When the billet is formed, the press also applies a cover to the container to keep the material free of contamination until a later heat treatment or forging operation. Mechanism is provided for removing the completed billet or mold from the press and insertion of a new container.

Abstract: In a compacting press, the container in which the material is compacted is sealed by a cover which is positioned in the open end of the filled container before the container is removed from the press. The cover positioning device is movable into and out of operative position to permit operation of the press and the apparatus is remotely controlled externally of the vacuum chamber in which the press is located.

Abstract: Apparatus for supporting a conveyor tube in a furnace for rotation so as to translate particulate matter axially along the tube, and for axial movement of the tube to withdraw it from a device into which the particulate material is delivered from the tube.