Vacuum-Treated Carbon and Alloy Steel Forgings For Turbine Rotors and Shafts
Vacuum-Treated Carbon and Alloy Steel Forgings For Turbine Rotors and Shafts
Vacuum-Treated Carbon and Alloy Steel Forgings For Turbine Rotors and Shafts
for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
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TABLE 1 Chemical RequirementsA
Grade A Grade B Grade C Grade D Grade E
Ni-Mo-V Ni-Mo-V Ni-Cr-Mo-V Cr-Mo-V Ni-Mo-V
Carbon 0.22–0.30 0.22–0.30 0.28 0.25–0.35 0.30
Manganese 0.20–0.60 0.20–0.60 0.20–0.60 1.00 0.70
Phosphorus 0.012 0.012 0.012 0.012 0.025
Sulfur 0.012 0.012 0.015 0.015 0.025
B B B,C B B
Silicon
Nickel 3.20–3.70 3.20–3.70 3.25–4.00 0.75 2.00 min.
Chromium 0.75 0.75 1.25–2.00 1.05–1.50 0.75
MolybdenumD 0.40–0.60 0.40–0.60 0.25–0.60 1.00–1.50 0.25 min
Vanadium 0.04–0.12 0.04–0.12 0.05–0.15 0.20–0.30 0.03–0.12
E E E E E
Antimony
AluminumF 0.015 0.015 0.015 0.015 0.015
Equivalent ... ... ... Classes 2 and 3G ...
Specification A293
Grade Designation (replaced by
Specification A470)
A
Maximum or range, unless otherwise indicated.
B
0.10 % max, unless an alternative value, not in excess of 0.30 %, is specified in the purchase order.
C
0.15 to 0.30 % silicon is permitted for material that is subsequently VAR Processed.
D
Supplementary Requirement, see S1.
E
To be reported for information only on all Grades.
F
Total of soluble and insoluble.
G
Phosphorus of 0.035 max and sulfur of 0.035 max were specified for Specification A293.
4.4 Forging Process—The forging shall receive its hot mechanical properties shall be made after the second tempering
mechanical work under a press of ample power to adequately operation. Mechanical property tests after the first temper are
work the metal throughout the maximum section of the optional with the manufacturer.
forging. It is important to maintain the axial center of the 4.5.1.4 After heat treatment and subsequent rough machin-
forging in common with the axial center of the ingot. ing and axial boring (see 4.6.2 and 4.6.3), the forging shall be
4.5 Heat Treatment: stress-relieved at a temperature not more than 100°F [55°C]
4.5.1 The heat treatment for mechanical properties shall below the final tempering temperature, but not less than
consist of double-normalizing and tempering for Grades A, B, 1025°F [550°C].
D, and E and normalizing, quenching, and tempering for Grade 4.5.1.5 With the prior approval of the purchaser, the stress-
C. In normalizing treatments, the forging may be cooled in still relief temperature may approach, equal, or slightly exceed the
air or in an air blast at the manufacturer’s option. Faster final tempering temperature as a means of adjusting final
cooling rates for Grades A, B, D, and E may be used if strength or toughness. If the stress-relief temperature is within
authorized by the purchaser. These rates are obtained by liquid 25°F [14°C] of the final tempering temperature, or higher,
quenching, or by the addition of water sprays of fog to the air additional tension tests must be obtained (6.1.3).
blast. 4.6 Machining:
4.5.1.1 The first normalizing treatment shall be from well 4.6.1 Preliminary Rough Machining—All exterior surfaces
above the transformation temperature range. At the manufac- of the forging shall be machined prior to heat treatment for
turer’s option, this operation may be performed as a part of the mechanical properties.
preliminary treatment of the forging before preliminary ma-
4.6.2 Second Rough Machining—After heat treatment for
chining (see 4.6.1).
mechanical properties, all surfaces of the forging shall be rough
4.5.1.2 The second normalizing or quenching treatment
machined prior to stress relief and the stability test.
shall be from above the transformation range but below the first
normalizing temperature described in 4.5.1.1. This treatment 4.6.3 Axial Bore:
shall be performed after preliminary machining (see 4.6.1). 4.6.3.1 Forgings shall be bored to permissible bore size and
4.5.1.3 The final tempering temperature for Grades A, B, C, tolerance when required by the purchaser’s drawing.
and E shall be not less than 1075°F [580°C] and for Grade D 4.6.3.2 Forgings may be bored to limits agreed to by the
not less than 1200°F [650°C]. With prior purchaser approval, a purchaser, or indicated on the purchaser’s drawing, to remove
second tempering operation shall be performed prior to the objectionable center conditions revealed by ultrasonic exami-
operations described in 4.6.2 and 4.6.3 to complete the heat nation.
treatment cycle. This second temper will be in place of the 4.6.3.3 Unless otherwise specified by the purchaser, the
stress relief specified in 4.5.1.4 and 4.5.1.5 and the tempera- manufacturer may bore the forging at any time prior to stress
tures applied to the second temper will meet the temperature relief (see Supplementary Requirement S2).
limits in 4.5.1.4. However, with the prior approval of the 4.6.4 Machining to Purchaser’s Requirements for
purchaser, the second tempering temperature may be equal, or Shipment—The forging as shipped shall conform to the finish
slightly exceed, the first tempering temperature as a means of and dimension requirements specified on the purchaser’s
adjusting final strength or toughness. The required tests for drawing or order.
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5. Chemical Composition purchaser’s drawing. The specimens shall be Charpy V-notch,
5.1 The steel shall conform to the requirements for chemical as shown in Test Methods and Definitions A370. The notch
composition prescribed in Table 1. direction of the Charpy specimens shall be tangential.
5.2 Chemical Analysis: 6.3 The properties at the axial bore region may not neces-
5.2.1 Product Analysis—The manufacturer shall make a sarily be the same as those determined at the surface radial or
product analysis from each forging. The sample location and axial prolongation regions. Slight variations in chemical
product analysis tolerances shall conform to Specification homogeneity, different cooling rates, presence of non-
A788/A788M. metallics, and orientation of the test samples are some of the
factors that can contribute to the difference. If axial bore
6. Mechanical Properties properties are required, they can be obtained through Supple-
mentary Requirement S2.
6.1 Tension Test:
6.1.1 The steel shall conform to the tensile requirements of 7. Dimensions, Tolerances, and Finish
Table 2.
6.1.2 The number and location of tension test specimens 7.1 The steel shall conform to the tensile requirements of
shall be as specified on the drawing furnished by the purchaser. Table 2.
6.1.3 Final acceptance tests shall be made after heat treat- 7.2 The finish on each forging shall conform to the finish
ment of the forging for mechanical properties prior to stress specified on the purchaser’s drawing or order.
relief, unless the stress relief temperature is within 25°F [14°C]
of the tempering temperature, or higher, in which case check 8. Nondestructive Tests
tests shall be made after the stress relief treatment and reported 8.1 General Requirements:
to the purchaser. The purchaser may require check tests after 8.1.1 The forgings shall be free of cracks, seams, laps,
completion of all heating cycles, including stress relief and the shrinkage, and similar imperfections.
heat stability tests. 8.1.2 The purchaser may request ultrasonic, magnetic
6.1.4 Testing shall be performed in accordance with the particle, dye penetrant, etch, or other accepted nondestructive
latest revision of Test Methods and Definitions A370. Tension examination necessary to evaluate imperfections and ensure
specimens shall be the standard 0.5-in. diameter by 2-in. gage compliance with this requirement.
length [or 12.5- by 50.0-mm type] as shown in Test Methods 8.2 Ultrasonic Examination:
and Definitions A370. 8.2.1 An ultrasonic examination shall be made on the
6.1.5 The yield strength prescribed in Table 2 shall be machined forging at the manufacturer’s plant. This examina-
determined by the offset method of Test Methods and Defini- tion shall be made in accordance with Practice A418/A418M to
tions A370. demonstrate freedom from rejectable internal indications.
6.2 Impact Test: 8.2.2 The ultrasonic examination shall be made from all
6.2.1 The steel shall conform to the requirements for notch available surfaces prior to removal of test specimens that
toughness (both transition temperature and room temperature would interfere with complete testing of the forging.
impact values) prescribed in Table 2. 8.2.3 Forgings with recordable ultrasonic indications shall
6.2.2 The impact specimens shall be machined from radial be referred to the purchaser for evaluation based on the nature,
bars taken from the main body of the forging, as shown in the frequency, and location of indications, both stationary and
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traveling. If the ultrasonic indications are considered 10.3 If complete retreatment, including normalizing or
objectionable, it shall be determined by conventional or mutu- quenching, is necessary after boring, the feasibility of retreat-
ally acceptable examination procedures whether the forging ing portions of the bore core in the bore of the forging shall be
will be rejected. discussed between manufacturer and purchaser and a proce-
8.3 Internal Examination: dure agreed upon before retreatment.
8.3.1 Axial bore, when specified for internal visual
examination, shall be in accordance with the drawing furnished 11. Certification and Reports
by the purchaser. The drawing shall specify the nominal 11.1 The manufacturer shall furnish to the purchaser the
dimensions of the bore. number of properly certified test reports specified on the
8.3.2 If objectionable conditions are encountered during the purchase order.
internal examination of the bore, the manufacturer shall notify
the purchaser of the location and nature of the condition. 11.2 The following items shall be reported:
Further action shall be taken only after mutual agreement 11.2.1 Purchaser order number,
between the manufacturer and purchaser. 11.2.2 Forging identification number,
11.2.3 Specification number, grade, and class,
9. Stability Test
11.2.4 Heat number (or numbers), heat chemical analysis
9.1 Each Grade D and E forging shall be subjected to a heat (or analyses), and product, chemical analysis,
stability test at the manufacturer’s plant in accordance with the 11.2.5 Results of all acceptance tests for mechanical prop-
latest issue of Specification A472/A472M to determine the erties and notch toughness,
stability or freedom from tendency to distort during high-
11.2.6 Results of all nondestructive examinations plus
temperature operating conditions.
sketches indicating the location and orientation of all record-
9.2 The stability test shall be conducted after the forging has able indications,
been stress relieved in accordance with 4.5.1.4. 11.2.7 Final heat treatment cycle including austenitizing and
NOTE 1—If agreed upon between the manufacturer and the purchaser, tempering temperatures, holding times, and cooling methods,
the stress relief may be performed as part of the stability test. and
9.3 Stability Test Requirements: 11.2.8 Results of any supplementary requirements that have
9.3.1 The purchaser’s drawing shall indicate the minimum been specified.
portion of the forging to be included within the heating
chamber during the stability test. 12. Packaging and Package Marking and Loading
9.3.2 The purchaser’s drawing or order shall indicate the 12.1 Test specimens shall be identified with numbers corre-
minimum stability test temperature. sponding to the forging identification numbers plus numbers
10. Retreatment corresponding to test location and type if specified on the
purchaser’s drawings or order.
10.1 If the results of the mechanical tests of any forging do
not conform to the requirements specified, the manufacturer 12.2 The axial bores of bored forgings shall be protected
may retreat the forging one or more times, but not more than and suitably plugged to prevent damage or corrosion during
three additional times, without the approval of the purchaser. shipment or storage.
10.2 If bore core properties are specified under Supplemen-
tary Requirement S2 and retemper is necessary after boring, 13. Keywords
the remaining portions of the bore core shall be replaced in the 13.1 steel forgings; turbine rotors; turbine shafts; vacuum-
bore during retemper. treated steel
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SUPPLEMENTARY REQUIREMENTS
The following supplementary requirements shall apply only when specified by the purchaser in the
inquiry, contract, and order. Details of these supplementary requirements shall be agreed upon by the
manufacturer and purchaser.
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S7.3.2 When the electrodes from different master heats are S10. Heat Treatment After Machining of Disks or Wheels,
remelted sequentially to produce the ingot, an analysis shall be or Both
made in each zone of the remelted ingot corresponding to each S10.1 When agreed upon between the manufacturer and the
electrode from each master heat represented. Each such analy- purchaser, the heat treatment for mechanical properties shall be
sis shall comply with the heat analysis requirements of the performed after additional machining of the material between
material grade specified. The zone analysis of the portion of the the rotor discs or wheels, or both. This agreement should also
remelt ingot used in a forging shall be reported, and their address the following:
average shall be the heat analysis of the forging. S10.1.1 Machined finish allowances, radii, and surface fin-
ish before and after the heat treatment for mechanical proper-
S8. Hydrogen Determination ties.
S8.1 A hydrogen determination shall be made. The accept- S10.1.2 Locations of tension test specimens and test direc-
able hydrogen limit as well as the stage in processing when tion.
sampling, the sample preparation procedure and the method of S10.1.3 Locations of impact test specimens and notch
analysis shall be as agreed upon between manufacturer and direction.
purchaser. S10.1.4 Impact energy and FATT requirements.
S10.1.5 Ultrasonic examination of the cylindrical forging
S9. Magnetic Particle Examination shapes following the preliminary heat treatment.
S10.1.6 Ultrasonic examination of the disc or wheels, or
S9.1 A magnetic particle examination of the complete both, and remaining shaft diameters after the heat treatment for
exterior and bore surfaces of the machined forging shall be mechanical properties.
made at the forging manufacturer’s plant. The examination S10.1.7 Magnetic particle examination after the heat treat-
shall be performed in accordance with the latest issue of ment for mechanical properties.
Practice A275/A275M.
S9.2 Forgings with either cracks or linear indications of any S11. Heat Stability Testing
length are subject to rejection unless they can be removed to S11.1 Each forging shall be subjected to a heat stability test
the purchaser’s satisfaction. in accordance with Section 9, regardless of grade.
APPENDIXES
(Nonmandatory Information)
X1.1 Heat stability testing provides assurance that the ordering a Grade A, B, or C rotor forging, but lacking
process controls utilized in the manufacture of a rotor forging experience with rotor forgings produced by the current
have produced a thermally stable product. This test is optional manufacturer, may obtain the desired assurance by invoking
for Grades A, B, and C in this specification. Customers Supplementary Requirement S11.
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