Isothermal Roll Forging of Compressor Blades

Isothermal roll forging is being applied to the manufacture of gas turbine compressor blades. The process can produce a compressor blade to net section in a single roll forge pass from simple barstock using force feed to gather the metal for the root section. Heating is performed with simultaneous electrical resistance heating of precision molybdenum alloy dies and the blade to a set forging temperature. Good surfaces are produced together with thin flash thereby minimizing final operations for clean-up and inspection. A manufacturing process has been selected and demonstrated under the U. S. Army’s Manufacturing Methods and Technology Program. Projected costs show potential for significant cost reduction. Establishment of this manufacturing process is in progress.