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Alloy 718 VAR ingots of 860 mm (34 inches) in diameter were successfully melted and processed to billets and finished products in the range from 355 to 660 mm (14 to 26 inches) in diameter. A special melting route was followed resulting in a quadruple melted material: initial melting of raw materials in an electric arc furnace, liquid metal refining in an Argon-Oxygen Decarburization (AOD) converter, air pouring into molds and solidification, vacuum melting of AOD ingots and pouring into electrodes using a Vacuum Induction Degassing and Pouring (VIDP) furnace and double Vacuum Arc Remelting (VAR) computer-controlled processing. Double VAR ingots were homogenized and hot forged on a 50 MN open-die, computercontrolled hydraulic forging press to ultrasonic sound billets. Billets were macro examined and show no evidence of freckles, white spots, radial segregations or ring pattern. Billet microstructure showed an uniform grain size throughout the billet cross-section. Proper solution annealing and age hardening resulted in microstructure and mechanical properties matching requirements of both aerospace and oil patch specifications. Results of this study demonstrate the feasibility of large alloy 718 billets and finished bars from thirty-four inches ingots of comparable quality to billets and bars manufactured from standard twenty inches ingots and present an opportunity for manufacturing larger wrought products of alloy 718 for power generation and aerospace applications.

Alloy 718 Large Ingots Studies