Which superalloys are most commonly used in rough forging for aerospace components?

Performance Requirements for Rough-Forged Aerospace Components

Rough forging is used in the early forming stage of aerospace component manufacturing to break down cast structures and establish preforms for subsequent finishing processes. Materials must provide excellent hot workability, controlled grain refinement, and resistance to cracking during plastic deformation. Superalloys selected for rough forging must strike a balance between workability and high-temperature strength to ensure a stable foundation for subsequent precision forging or machining.

Commonly Used Superalloys for Rough Forging

Nickel-based superalloys are widely employed for aerospace rough forging due to their high resistance to thermal fatigue. Alloys such as Inconel 718 and high-performance grades like Inconel 713LC are frequently used as initial forgings for turbine disks, structural brackets, and engine mounts. These alloys offer good hot workability and enable stable billet formation before more advanced shaping methods are applied.

For components requiring enhanced resistance to creep and stress-induced cracking, aerospace manufacturers may opt for cobalt-based alloys like Stellite 6, particularly in high-wear areas exposed to vibration and aerodynamic load cycling.

Processing and Post-Treatment Considerations

After rough forging, secondary processing techniques such as precision forging or hot isostatic pressing (HIP) are typically applied to improve grain alignment and remove internal porosity. Hardening treatments and microstructure optimization via controlled superalloy heat treatment further enhance fatigue resistance and dimensional stability for critical aerospace components.

Inspection and validation using advanced tools like material testing and analysis are required to ensure that rough-forged superalloys meet aerospace manufacturing standards before transitioning to final shaping operations.