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- W2326453310 abstract "Clean Metal Spray Forming (CMSF) is a new process in which the melt pool from an Electroslag Refining (ESR) furnace is used as the source for a liquid metal stream to be directly processed via spray forming. The process takes advantage of the refining function of the ESR process and the economy of the spray forming process to yield material that is oxide-free, tinegrained, equiaxed, homogeneous, and thus acceptable for fatigue-life critical applications. The controlled transfer of liquid metal from the ESR pool to the spray forming system is performed using a ceramic-free cold-walled-induction guide, which is a segmented induction heated copper funnel. A pilot plant for development of the concept using nickel-based alloys has been constructed and is operational. Oxide cleanliness, microstructure, and mechanical properties of Alloy 718 processed through the system will be discussed. Introduction Ceramic inclusions play a significant role in the low-cycle-fatigue life of components made from superalloys [ 1,2]. Mechanistically, a ceramic inclusion is more brittle than surrounding metal and will crack early in life, possibly as early as the first loading cycle. The cracked inclusion acts as a crack starter for the surrounding metal and may lead to early fatigue failure. Since a large fraction of the fatigue life of any part occurs while cracks are short, it is important to eliminate or limit the size of the ceramic inclusions. This requirement poses a metals processing challenge that has been aggressively attacked in the cast & wrought industry and in the powder metallurgy industry. In the cast & wrought industry, a high level of cleanliness is achieved using a triple melt procedure in which Vacuum Induction Melting (VIM) is used to achieve composition, Electroslag Refining (ESR) is used to achieve cleanliness [3], and Vacuum Arc Remelting (VAR) is used to achieve microstructure and homogeneity. In the powder metallurgy industry, cleanliness is achieved by sieving the powder, and through careful handling during subsequent canning, vacuum degassing, and extrusion. The primary oxide removing process in cast & wrought processing is the ESR step and the primary oxide removing step in powder metallurgy is the sieve step. Superalloys 7X3,625,706 and Various Derivatives Edited by E.A. Loria The Minerals, Metals &Materials Society, 1997" @default.
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- W2326453310 date "1997-01-01" @default.
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- W2326453310 title "Clean Metal Spray Forming" @default.
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- W2326453310 doi "https://doi.org/10.7449/1997/superalloys_1997_27_36" @default.
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