Distortions induced in turbine blades by hot forging and cooling

Geometrical distortions of hot forged thin components are one of the main causes that force process designers to work with significant allowances. Their identification in the early stages of process design would permit changing the process parameters in order to compensate them during cooling after the hot forging process. This paper presents a novel approach to evaluate geometrical distortions of hot forged components characterized by complex and thin geometrical features, such as turbine blades. A thermo-mechanical–metallurgical model of both the forging and cooling phases is developed, in order to investigate the effects of different cooling rates after forging on the component final geometry and then to choose those cooling parameters that assure minimal distortions. The developed models are calibrated through extensive experimental campaigns, involving both laboratory experiments and on-field measurements during industrial productions. Thermal boundary conditions are identified through on-field measurements of blade surface temperatures, while material behaviour regarding flow stress determination and phase transformation-related parameters is obtained through compression and tensile tests with a dilatometer aid, all carried out in the range of temperatures of interest for the forging and the cooling phases.