Abstract: A process for producing a rotor, the rotor formed thereby, as well as turbines in which such a rotor is installed. 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. The effects of the transition zone can be mitigated by modeling the transition zone and then off-center machining the forging so that the axis of rotation of the machined monolithic rotor is more centrally located with respect to the transition zone.

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.

Abstract: A process for producing a rotor, the rotor formed thereby, as well as turbines in which such a rotor is installed. 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. The effects of the transition zone can be mitigated by modeling the transition zone and then off-center machining the forging so that the axis of rotation of the machined monolithic rotor is more centrally located with respect to the transition zone.

Abstract: A monolithic rotor comprising first and second rotor regions axially aligned within the monolithic rotor and a transition zone therebetween. The first and second rotor regions are formed of different alloys and the transition zone having a composition that differs from and varies between the first and second rotor regions. The first rotor region is located within a high pressure region of the monolithic rotor and is formed from an alloy chosen from the group consisting of CrMoV low alloy steels, martensitic stainless steels containing about 11 to about 14 weight percent chromium, Fe—Ni alloys, and nickel-base alloys. The second rotor region is located within a low pressure region of the monolithic rotor and is formed from an alloy chosen from the group consisting of NiCrMoV low alloy steels and martensitic stainless steels containing about 11 to about 14 weight percent chromium.