Method of producing multiple microstructure components

Abstract

Methods are provided for manufacturing turbine disks each having a hub surrounded by a rim, the hub having a first microstructure and the rim having a second microstructure that is coarser than the first microstructure, the methods employing a first powder alloy having a first gamma prime solvus temperature and a second powder alloy having a second gamma prime solvus temperature that is less than the first gamma prime solvus temperature. One method includes the steps of forming an ingot from the first and second powder alloys, the ingot having an inner section having the first microstructure and an outer section having a microstructure that is less coarse than the second microstructure, and exposing the ingot to a temperature between the first and second gamma prime solvus temperatures while forming the ingot into a plurality of turbine disks to transform the microstructure of the outer section into the second microstructure.

1 . A method of manufacturing turbine disks each having a hub surrounded by a rim, the hub having a first microstructure and the rim having a second microstructure that is coarser than the first microstructure, the method employing a first powder alloy having a first gamma prime solvus temperature and a second powder alloy having a second gamma prime solvus temperature that is less than the first gamma prime solvus temperature and comprising the steps of: 
 forming an ingot from the first and second powder alloys, the ingot having an inner section having the first microstructure and an outer section having a microstructure that is less coarse than the second microstructure; and    exposing the ingot to a temperature between the first and second gamma prime solvus temperatures while forming the ingot into a plurality of turbine disks to transform the microstructure of the outer section into the second microstructure.    
     
     
         2 . The method of  claim 1 , wherein the step of forming the ingot comprises: 
 containerizing the first and the second powder alloys in a container having a first volume and a second volume surrounding the first volume, respectively;    pressurizing the first and second powder alloys at a pressure of between about 10 ksi and about 30 ksi at a temperature below the second gamma prime solvus temperature to form the inner and outer sections of the ingot, respectively.    
     
     
         3 . The method of  claim 2 , wherein the container has a first diameter and the method further comprises extruding the first and second powder alloys through a second container having a second diameter that is smaller than the first diameter.  
     
     
         4 . The method of  claim 1 , wherein the first microstructure has a plurality of grains each having a grain size of between about 5 microns and about 10 microns and the second microstructure has a plurality of grains each having a grain size of between about 15 microns and about 30 microns.  
     
     
         5 . The method of  claim 1 , wherein the step of forming the ingot comprises: 
 depositing the first powder alloy into a first volume;    pressurizing the first powder alloy at a pressure of between about 10 ksi and about 30 ksi at a temperature below the first gamma prime solvus temperature to form a first component;    depositing the second powder alloy into a second volume configured to surround the first volume;    pressurizing the second powder alloy at a pressure of between about 10 ksi and about 30 ksi at a temperature below the second gamma prime solvus temperature to form a second component;    containerizing the first and the second components such that the first component is surrounded by the second component; and    pressurizing the containerized first and second components at a pressure of between about 10 ksi and about 30 ksi at a temperature below the first gamma prime solvus temperature to form the ingot, wherein the first and second components transform into the inner and outer sections of the ingot, respectively.    
     
     
         6 . The method of  claim 5 , further comprising: 
 machining the first component into a rod; and    machining the second component into a cylinder.    
     
     
         7 . The method of  claim 1 , wherein the step of forming the ingot comprises: 
 depositing the first powder alloy into a first volume;    pressurizing the first powder alloy at a pressure of between about 10 ksi and about 30 ksi while exposed to a temperature below the first gamma prime solvus temperature to form a first component having the first microstructure; and    containerizing the first component and the second powder alloy, wherein the second powder alloy surrounds the first component; and    pressurizing the containerized first component and second powder alloy at a pressure of between about 10 ksi and about 30 ksi at a temperature below the second gamma prime solvus temperature to transform the first component into the ingot inner section and the second powder alloy into the ingot outer section.    
     
     
         8 . The method of  claim 1 , wherein the step of forming the ingot comprises: 
 depositing the second powder alloy into a volume;    pressurizing the second powder alloy at a pressure of between about 10 ksi and about 30 ksi while exposed to a temperature below the second gamma prime phase solvus temperature to form a component having a microstructure that is less coarse than the second microstructure; and    containerizing the second powder alloy component and the first powder alloy, wherein the first powder alloy surrounds the second powder alloy component; and    pressurizing the containerized second powder alloy component and first powder alloy at a pressure of between about 10 ksi and about 30 ksi at a temperature below the second gamma prime phase solvus temperature to transform the second powder alloy component into the ingot outer section and the first powder alloy into the ingot inner section.    
     
     
         9 . The method of  claim 1 , wherein the step of exposing further comprises: 
 slicing the ingot into a plurality of disks; and    machining one disk of the plurality of disks into the turbine disk.    
     
     
         10 . A method of manufacturing a turbine disk having a hub surrounded by a rim, the hub having a first microstructure and the rim having a second microstructure that is coarser than the first microstructure, the method employing a first powder alloy having a first gamma prime solvus temperature and a second powder alloy having a second gamma prime solvus temperature that is less than the first gamma prime solvus temperature and comprising the steps of: 
 forming an ingot from the first and second powder alloys, the ingot having an inner section having the first microstructure and an outer section having the second microstructure; and    exposing the ingot to a temperature below the first gamma prime solvus temperature while forming the ingot into a plurality of turbine disks.    
     
     
         11 . The method of  claim 10 , wherein the step of forming the ingot comprises: 
 containerizing the first and the second powder alloys in a container having a first volume and a second volume surrounding the first volume, respectively;    pressurizing the first and second powder alloys at a pressure of between about 10 ksi and about 30 ksi at a temperature between the first and the second gamma prime solvus temperatures to form the inner and outer sections of the ingot, respectively.    
     
     
         12 . The method of  claim 10 , wherein the first microstructure has a plurality of grains each having a grain size of between about 5 microns and about 10 microns and the second microstructure has a plurality of grains each having a grain size of between about 15 microns and about 30 microns.  
     
     
         13 . The method of  claim 10 , wherein the step of forming the ingot comprises: 
 depositing the first powder alloy into a first volume;    pressurizing the first powder alloy at a pressure of between about 10 ksi and about 30 ksi at a temperature below the first gamma prime solvus temperature to form a first component;    containerizing the first component and the second powder alloy such that the second powder alloy surrounds the first component; and    pressurizing the containerized first component and second powder alloy at a pressure of between about 10 ksi and about 30 ksi at a temperature between the first and second gamma prime solvus temperatures to transform the first component into the ingot inner section and the second powder alloy into the ingot outer section.    
     
     
         14 . The method of  claim 13 , further comprising: 
 machining the first component into a rod; and    machining the second component into a cylinder.    
     
     
         15 . The method of  claim 10 , wherein the step of forming the ingot comprises: 
 depositing the second powder alloy into a volume;    pressurizing the second powder alloy at a pressure of between about 10 ksi and about 30 ksi at a temperature that is below the second gamma prime solvus temperature to form a component;    containerizing the second powder alloy component and the first powder alloy, wherein the second powder alloy component surrounds the first powder alloy; and    pressurizing the containerized second powder alloy component and first powder alloy at a pressure of between about 10 ksi and about 30 ksi at a temperature between the first and second gamma prime solvus temperatures to transform the second powder alloy component into the ingot inner section and the second powder alloy into the ingot outer section.    
     
     
         16 . The method of  claim 10 , wherein the step of forming the ingot comprises: 
 depositing the second powder alloy into a second volume;    pressurizing the second powder alloy at a pressure of between about 10 ksi and about 30 ksi at a temperature that is above the second gamma prime solvus temperature to form a component;    containerizing the second powder alloy component and the first powder alloy, wherein the second powder alloy component surrounds the first powder alloy; and    pressurizing the containerized second powder alloy component and first powder alloy at a pressure of between about 10 ksi and about 30 ksi at a temperature between the first and second gamma prime solvus temperatures to transform the second powder alloy component into the ingot inner section and the second powder alloy into the ingot outer section.    
     
     
         17 . The method of  claim 16 , further comprising: 
 machining the first component into a rod; and    machining the second component into a cylinder.    
     
     
         18 . The method of  claim 10 , wherein the step of exposing further comprises: 
 slicing the ingot into a plurality of disks; and    machining one disk of the plurality of disks into the turbine disk.