METHOD FOR MANUFACTURING AN ARTICLE FROM A CONSOLIDATED METALLIC POWDER COMPOSITION

Abstract

A method for manufacturing an article includes consolidating a metallic powder composition into a consolidated preform, applying a supersolidus heat treatment to the consolidated preform during or after consolidating the metallic powder composition to yield a heat treated preform, and reducing a cross-sectional area of the heat treated preform by thermo-mechanical processing to yield a processed preform.

Claims

1. A method for manufacturing an article, the method comprising: consolidating a metallic powder composition into a consolidated preform; applying a supersolidus heat treatment to the consolidated preform during or after consolidating the metallic powder composition to yield a heat treated preform; and reducing a cross-sectional area of the heat treated preform by thermo-mechanical processing to yield a processed preform.

2. The method of claim 1, wherein the metallic powder composition comprises at least one of an alloy, an intermetallic, and a metal-matrix composite.

3. The method of claim 1, wherein the supersolidus heat treatment is applied during the consolidating of the metallic powder composition into the consolidated preform.

4. The method of claim 1, wherein the supersolidus heat treatment is applied after consolidating the metallic powder composition into the consolidated preform.

5. The method of claim 1, wherein consolidating the metallic powder composition results in formation of prior particle boundaries in the consolidated preform, and wherein the supersolidus heat treatment eliminates at least a portion of the prior particle boundaries.

6. The method of claim 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 99 percent.

7. The method of claim 1, wherein the thermo-mechanical processing comprises a cogging process.

8. The method of claim 1, wherein the thermo-mechanical processing comprises a rotary incremental forming process.

9. The method of claim 1, wherein the thermo-mechanical processing comprises: reducing the cross-sectional area of the heat treated preform via an initial forming pass so that the heat treated preform has a decreased cross-sectional area; and reducing the decreased cross-sectional area of the heat treated preform via a subsequent forming pass by a greater percentage than that, by which the cross-sectional area of the heat treated preform was reduced during the initial forming pass.

10. The method of claim 9, wherein the initial forming pass reduces the cross-sectional area of the heat treated preform by at most 2 percent.

11. The method of claim 9, wherein the subsequent forming pass reduces the decreased cross-sectional area of the heat treated preform by at least 2 percent.

12. The method of claim 1, wherein the thermo-mechanical processing is performed at a temperature (in degrees Kelvin) that is at most 95 percent of a solidus temperature (in degrees Kelvin) of the metallic powder composition.

13. The method of claim 1, wherein the thermo-mechanical processing is performed at a temperature (in degrees Kelvin) that is in a temperature range of 60 percent to 90 percent of a solidus temperature (in degrees Kelvin) of the metallic powder composition.

14. The method of claim 1, wherein the thermo-mechanical processing is performed at a temperature (in degrees Kelvin) that is in a temperature range of 40 percent to 60 percent of a solidus temperature (in degrees Kelvin) of the metallic powder composition.

15. The method of claim 1, wherein the thermo-mechanical processing is performed at an average equivalent strain rate that ranges from 0.00001 s.sup.1 to 100 s.sup.1.

16. The method of claim 1, wherein the thermo-mechanical processing reduces a porosity of the heat treated preform.

17. The method of claim 1, further comprising a step of annealing the heat treated preform after the thermo-mechanical processing.

18. The method of claim 1, further comprising shaping the processed preform to a final shape after the thermo-mechanical processing.

19. A method for manufacturing an article, the method comprising: consolidating a metallic powder composition into a consolidated preform; applying a supersolidus heat treatment to the consolidated preform during or after consolidating the metallic powder composition to yield a heat treated preform; and reducing a cross-sectional area of the heat treated preform by at least one of a cogging process and a rotary incremental forming process to yield a processed preform.

20. A wrought metallic article manufactured according to a method comprising: consolidating a metallic powder composition into a consolidated preform; applying a supersolidus heat treatment to the consolidated preform during or after consolidating the metallic powder composition to yield a heat treated preform; and reducing a cross-sectional area of the heat treated preform by thermo-mechanical processing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a block diagram of a method, according to one or more examples of the subject matter, disclosed herein, for manufacturing an article from metallic powder compositions;

[0013] FIG. 2 is a block diagram of aircraft production and service methodology; and

[0014] FIG. 3 is a schematic illustration of an aircraft.

DETAILED DESCRIPTION

[0015] The method of the present description is a process for manufacturing metallic articles from metallic powder compositions. Referring to FIG. 1, the method (100) includes, at block (110), consolidating a metallic powder composition into a consolidated preform, at block (120), applying a supersolidus heat treatment to the consolidated preform during or after consolidating the metallic powder composition to yield a heat treated preform, and, at block (130), reducing a cross-sectional area of the heat treated preform by thermo-mechanical processing to yield a processed preform.

[0016] The metallic powder composition serves as the foundational material in the manufacturing process, and its formulation determines the final article's mechanical, thermal, and chemical properties. The formulation of the metallic powder composition can be selected to meet particular requirements such as strength, durability, corrosion resistance, tolerance to high temperatures, and manufacturability.

[0017] The metallic powder composition can, for example, include an alloy, an intermetallic, a metal-matrix composite, or combinations thereof. An alloy is a combination of two or more metals or a metal and a nonmetal, which may have distinct properties from its constituent elements. An intermetallic is a compound of two or more metals that has a stoichiometry and crystal structure different from those of the pure metals. A metal-matrix composite includes a material having a metal matrix embedded with reinforcing materials, such as another metal, a ceramic, or an intermetallic, which can improve the properties of the metal matrix. The metallic powder composition can include of any of these materials or combinations thereof, depending on the desired characteristics and applications of the final article. For example, the metallic powder can comprise of an alloy and an intermetallic, an intermetallic and a metal-matrix composite, an alloy and a metal-matrix composite, or a mixture of all three.

[0018] The metallic powder composition may have a uniform composition, or the metallic powder composition may have a blended composition in which the metallic powder composition comprises, for example, a blend of a first metallic powder component having a first composition with a second metallic powder component having a second composition to yield the metallic powder composition. For a uniform composition, the metallic powder can have a substantially consistent and homogeneous chemical composition throughout. For a blended composition, the metallic powder composition can be formed by mixing two or more different metallic powders, each having a distinct chemical composition, to create a new blended metallic powder composition upon consolidation. The blended composition can also be used to introduce additional elements or phases into the metallic powder, such as alloying elements, intermetallics, ceramics, or metal-matrix composites, to modify the formulation of the final article.

[0019] Specific examples of the metallic powder composition include an aluminum alloy, a metal-matrix composite comprising aluminum, a titanium alloy, a metal-matrix composite comprising titanium, a superalloy, an iron alloy, a metal-matrix composite comprising iron, a nickel alloy, a metal-matrix composite comprising nickel, a cobalt alloy, a metal-matrix composite comprising cobalt, a refractory metal alloy, a metal-matrix composite comprising a refractory metal, a copper alloy, a metal-matrix composite comprising copper, a precious-metal alloy, a metal-matrix composite comprising a precious metal, a zirconium alloy, a metal-matrix composite comprising zirconium, a hafnium alloy, a metal-matrix composite comprising hafnium, a rare-earth-metal alloy, a metal-matrix composite comprising a rare-earth metal, a magnesium alloy, a metal-matrix composite comprising magnesium, a steel, a metal-matrix composite comprising steel, an intermetallic, a complex concentrated alloy, a metal-matrix composite comprising a complex concentrated alloy, a high-entropy alloy, a metal-matrix composite comprising a high-entropy alloy, a medium-entropy alloy, a metal-matrix composite comprising a medium-entropy alloy, a multicomponent alloy, a metal-matrix composite comprising a multicomponent alloy, or combinations thereof. Each example of the metallic powder composition, whether an alloy, a metal-matrix composite, or an intermetallic, brings distinct properties that may be significant for the intended use of the final article. For instance, aluminum alloys and metal-matrix composites containing aluminum may be chosen for their lightweight and high corrosion resistance, whereas titanium alloys and their composites can offer high strength-to-weight ratios. The formulation of these various metallic powders allows for the production of components that meet the demands of various specific environments and applications.

[0020] In a specific example, the metallic powder composition may include a nickel alloy. A nickel alloy, specifically for the manufacturing of nickel-based superalloys, may be selected due to their properties which make them desirable for demanding applications. Nickel superalloys may be used for their resistance to thermal creep deformation, excellent mechanical strength, and stability across a wide range of temperatures, making them suitable for use in high-temperature, high-stress environments. The methods of the present description are particularly relevant for addressing challenges that occur during processing of powder metallurgy nickel-based superalloys into wrought products. Products created from powder metallurgy, specifically those based on nickel alloys, need to exhibit a certain level of ductility. Ductility refers to the ability of the material to deform under tensile stress, which is important for the subsequent processing of the consolidated preforms into final shapes or forms. Historically, it has been challenging to process nickel-based products, initially produced via standard consolidation techniques, into additional forms or shapes. These challenges arise from the inherent material properties of such nickel alloys, including high melting points and tendencies to retain prior particle boundaries throughout subsequent processes. These properties can complicate further shaping or machining of the consolidated preforms. The methods of the present description address such challenges though applying a supersolidus heat treatment to the consolidated nickel-based alloys during or after consolidating the metallic powder composition, and reducing a cross-sectional area of the heat treated preform by thermo-mechanical processing as further explained below.

[0021] The form of the metallic powder composition is not limited and may include, for example, granular particles, spherical particles, spheroidal particles, fines, chips, flakes, and combinations thereof. The form of the metallic powder composition may depend on various factors, such as the method of production, the desired properties, and the intended application of the final product. For example, granular particles have irregular shapes and sizes, which may affect the packing density and flowability of the powder. Spherical or spheroidal particles have more uniform shapes and sizes, which may improve the packing density and flowability of the powder. Fines are very small particles that may have high surface area and reactivity, which may influence the sintering and consolidation behavior of the powder. Chips and flakes are thin and elongated particles that may have high aspect ratios and low density, which may affect the orientation and alignment of the powder during consolidation. Combinations of different forms of metallic powder may also be used to achieve a desired mixture of characteristics, such as density, strength, ductility, and conductivity. The form of the metallic powder composition may be controlled or modified by various techniques, such as atomization, milling, crushing, sieving, screening, blending, coating, or doping.

[0022] The metallic powder composition can be produced by any suitable method. Some examples of methods for producing metallic powder are atomization, mechanical milling, electrolysis, chemical reduction, thermal decomposition, or gas-phase synthesis. Each of these methods has advantages and disadvantages in terms of the cost, efficiency, quality, and properties of the resulting metallic powder. The choice of the method for producing metallic powder may depend on various factors, such as the type and composition of the metallic powder, the desired particle size and shape, the intended application and performance of the final product, and the availability and accessibility of equipment and materials. One of the common methods for producing metallic powder is atomization, which involves melting a metal or alloy and then spraying it into a stream of gas or liquid to break it into fine droplets that solidify into powder particles. Atomization can be performed using different techniques, such as gas atomization, water atomization, centrifugal atomization, or plasma atomization, depending on the type of metal, the desired particle size and shape, and the cost and efficiency of the process. Atomization can produce metallic powders with various characteristics, such as high purity, low oxygen content, uniform particle size distribution, and spherical or spheroidal morphology. Atomization can also be used to produce pre-alloyed powders, which are powders that contain more than one metallic element in a homogeneous phase, or composite powders, which are powders that contain more than one phase, such as metal matrix composites or metal-ceramic composites.

[0023] The consolidation of the metallic powder can include, but is not limited to pressing the metallic powder composition, isostatic pressing the metallic powder composition, hot pressing the metallic powder composition, hot isostatic pressing the metallic powder composition, vacuum hot pressing the metallic powder composition, cold pressing the metallic powder composition, cold isostatic pressing the metallic powder composition, sintering the metallic powder composition, cold isostatic pressing and sintering the metallic powder composition, sintering the metallic powder composition, spark plasma sintering the metallic powder composition, high strain rate densification, and combinations thereof.

[0024] Pressing involves compressing the metallic powder, such as in a die or a mold under a mechanical force, which reduces the porosity and increases the density of the powder. Pressing can be done at room temperature (cold pressing) or at elevated temperature (hot pressing). Cold pressing can produce products with high dimensional accuracy and low residual stress, but may require higher pressure and result in lower density and strength than hot pressing. Hot pressing can produce products with higher density and strength, but can resulting oxidation or other changes in the powder. Pressing can also be combined with sintering, which is a heat treatment that enhances the bonding between the powder particles.

[0025] Isostatic pressing involves compressing the metallic powder in a flexible container under a uniform pressure from a fluid or a gas, which can be applied at room temperature (cold isostatic pressing) or at elevated temperature (hot isostatic pressing). Isostatic pressing can produce products with high density and isotropic properties, as well as complex shapes and large sizes.

[0026] Vacuum hot pressing is a method of producing metallic products from powder. It involves applying high pressure and temperature to the powder in a vacuum environment, which can prevent it from oxidizing or getting otherwise contaminated. This method can result in products that have high density, homogeneity, and properties such as hardness, creep resistance, and dimensional stability. It can also be used to consolidate powders that are difficult to process, such as refractory or intermetallic materials, or to create products that have different compositions or functions in different layers, such as metal matrix composites or functionally graded materials.

[0027] Sintering involves heating the metallic powder near its melting point, which causes diffusion and bonding between the powder particles. Sintering can be performed in a furnace, a vacuum, or an inert atmosphere, depending on the type and composition of the metallic powder. Sintering can produce products with high density and strength, as well as improved mechanical, electrical, and thermal properties. However, sintering may also cause grain growth, shrinkage, and distortion of the powder, as well as oxidation or contamination from the surrounding environment.

[0028] Cold Isostatic Pressing followed by Sintering (CIP+Sinter) involves compressing the metallic powder in mold at high pressure and low temperature, which results in a green compact with uniform density and shape. The green compact is then sintered in a furnace to achieve full densification and bonding between the powder particles. CIP+Sinter can produce products with complex geometries and fine details, as well as good dimensional accuracy and surface finish. CIP+Sinter can also improve the mechanical, electrical, and thermal properties of the products, as well as reduce the porosity and defects in the powder.

[0029] Spark plasma sintering involves applying a pulsed electric current through the metallic powder, which generates heat and pressure simultaneously. Spark plasma sintering can produce products with high density and fine microstructure, as well as enhanced properties such as hardness, wear resistance, and corrosion resistance. Spark plasma sintering can also reduce the processing time and temperature, as well as prevent oxidation and contamination of the powder.

[0030] High strain rate densification involves subjecting the metallic powder to a high strain rate deformation, such as explosive compaction, shock loading, or dynamic forging. High strain rate densification can produce products with high density and refined microstructure, as well as improved properties such as ductility, toughness, and fatigue resistance. High strain rate densification can also enable the consolidation of hard-to-deform or reactive powders, as well as the synthesis of novel materials such as nanocrystalline or amorphous metals.

[0031] One of the challenges of powder metallurgy is to obtain a homogeneous and defect-free microstructure of the consolidated metallic powder composition. However, during the consolidation process, inhomogeneities may occur at the interfaces between the individual particles of the metallic powder, resulting in prior particle boundaries, or PPBs. PPBs can be formed from various sources, such as oxides, carbides, nitrides, or other impurities that are present on the surface of the powder particles, or from the incomplete diffusion of atoms across the interfaces. PPBs can have negative effects on the properties and subsequent processability of the consolidated metallic powder composition, such as reducing the strength, ductility, and fracture toughness, increasing the susceptibility to corrosion and fatigue cracking, or limiting the grain growth and recrystallization during heat treatment.

[0032] Supersolidus heat treatment is a process where the preform is heated above the solidus temperature of the metallic powder composition, but below the liquidus temperature (i.e., to a supersolidus temperature). This allows for partial melting of the preform during or after consolidation. Supersolidus heat treatment can eliminate the prior particle boundaries or a portion thereof and improve the homogeneity of the consolidated metallic powder composition. The elimination of PPB by supersolidus heat treatment involves the formation and migration of liquid phases at the prior particle boundaries formed at interfaces between the pre-existing powder particles before consolidation. The liquid phases can dissolve and transport the impurities or segregations that cause the PPBs. Supersolidus heat treatment can improve the homogeneity of the consolidated metallic powder composition by reducing the chemical and structural gradients across the particle boundaries, and enhancing the coherency and continuity of the microstructure.

[0033] The supersolidus heat treatment can be applied during or after consolidating the metallic powder composition. For example, the supersolidus heat treatment can be applied during a consolidation processes such as hot pressing or sintering, or the supersolidus heat treatment can be applied after any of the consolidation processes.

[0034] Kirkendall voids are pores that can form in the diffusion zone of a solid-state bond between two metals with different diffusion rates. They are caused by the faster diffusion of one metal species relative to another, creating vacancies that coalesce into voids. Kirkendall voids can weaken the bond strength and reduce the fatigue resistance of the resulting article.

[0035] One of the features of the present method is that it does not require a fully dense preform before the thermo-mechanical process. The relative density of the heat-treated preform, following the supersolidus heat treatment, can be lower than the maximum density of the respective material, such as 99.9 percent relative density or lower, 99.5 percent or lower, 99 percent or lower, 98 percent or lower, 97 percent or lower, 96 percent or lower, 95 percent or lower, 90 percent or lower, 85 percent or lower, or 80 percent or lower. The low relative density can be as a result of the consolidation process, kirkendall voids, or a combination thereof. The low relative density following the supersolidus heat treatment differentiates the present method from traditional methods which typically attempt to maximize the relative density at each step of the process. In contrast, the present method allows for a less-than-fully-dense preform, alleviating the need for energy- and time-intensive processes to reduce the relative density, and the method relies upon the thermo-mechanical processing to densify the preform.

[0036] After the supersolidus heat treatment, the preform is subjected to a thermo-mechanical processing (TMP) step, in which the cross-sectional area of the preform is reduced by applying mechanical forces at an elevated temperature. The TMP step can improve the microstructure and mechanical properties of the article, as well as reduce the porosity and increase the relative density. The TMP step can be performed by various methods, such as cogging, rotary incremental forming, or a combination thereof. These processes can achieve a substantial reduction of the cross-sectional area and result in a near-net-shape or net-shape article.

[0037] Cogging is a process where the supersolidus heat treated preform undergoes a series of compressive blows, which reduce its cross-sectional area and extend its length. This step is typically conducted through the use of forging presses or hammers and involves successive forging sequences. Such sequences can contribute to reducing the centerline porosity in the preform. The cogging operation applies global deformation, providing densification and shape to the preform. This process achieves significant objectives: on a macro-scale, it reduces the overall cross-sectional area of the preform. Simultaneously, the application of high pressures and deformation aids in breaking up and reducing the centerline porosity within the preform, as the spaces between particles are forced to close. This process results in densification of the material and refines the microstructure, enhancing the mechanical properties of the final product.

[0038] The method may also employ a rotary incremental forming process to refine the heat treated preform further. This process involves a tool that progressively and locally deforms the preform in a rotational manner, causing further reduction in its cross-sectional area. This process can be executed in several passes, each pass gradually changing the shape and size of the preform. Unlike cogging, which applies global deformation, rotary incremental forming induces localized plastic deformation at the contact point between the tool and the preform. This localized deformation effectively closes up surface pores, thereby reducing the surface porosity of the preform. The cumulative effect of the rotary incremental forming process is further densification of the surface of the preform and a refined surface microstructure. Both effects contribute to the improved properties of the final wrought metallic article. The process not only leads to further densification but also assists in achieving a better surface finish in the final metallic article.

[0039] The cogging process and the rotary incremental forming process can be conducted together in any order. The combination of these two processes together can provide a systematic reduction of porosity in the preform. While cogging primarily targets the centerline porosity, rotary incremental forming effectively reduces surface porosity. This dual approach ensures that the entire body of the preform, from the center to the surface, can be densified. This feature of the present method contributes to efficient manufacturing of a wrought metallic article with excellent mechanical properties, regardless of the order of the processes.

[0040] Cogging, as a metalworking process, is a versatile operation that can be performed in several ways, such as through open die forging, upsetting, pancaking, or billeting. These are all sub-processes that can be classified under the broader cogging process. Open die forging involves deforming the preform between two dies that do not completely enclose the material. The dies hammer or press the preform, reducing its cross-sectional area and lengthening it. This process allows for large reductions in cross-section and is particularly effective at reducing centerline porosity in the preform. Upsetting forging is a process where a preform is placed vertically, and force is applied to the top and bottom surfaces, decreasing its height. Pancaking is a similar process to upsetting but is used to describe a specific instance where the preform is deformed into a flatter shape. This can help to close centerline porosity and increase the density of the material. Billeting is another forging operation that aims to create a billet, a long, usually rectangular or cylindrical, piece of metal with a standardized cross-sectional size. This is achieved by deforming the preform through a series of hammer or press blows, reducing its cross-sectional area and lengthening it. Each of these processes can be used in the cogging step of the described method, depending on the specific requirements of the metallic article being manufactured. The key principle behind all these processes is the application of force to deform the preform, reducing its cross-sectional area and enhancing its densification. The choice between open die forging, upsetting, pancaking, and billeting would be made based on the desired final shape and size of the metallic article, as well as the specific properties of the metallic powder composition.

[0041] In the process of reducing the cross-sectional area of the heat treated preform via the cogging process, the approach may be staged or progressive, involving multiple forging passes each reducing the cross-sectional area by a different degree.

[0042] The cross-sectional area of the heat treated preform may be reduced via an initial forming pass of the cogging process that results in a modest reduction of the cross-sectional area. This initial pass can often be considered a softening or conditioning stage, where the preform is prepared for more significant deformation in subsequent stages. This initial pass does not significantly alter the dimensions of the preform, perhaps reducing the cross-sectional area by no more than 2 percent, 1.5 percent, or even as little as 1 percent. Despite this modest dimensional change, the initial forming pass plays a role in initiating the closure of centerline porosity in the preform, without damaging or fracturing the preform.

[0043] After the initial forming pass, further reduction of the decreased cross-sectional area of the preform is achieved via one or more subsequent forming passes of the cogging process. The subsequent pass reduces the cross-sectional area by a greater percentage than the initial forming pass. This could be a reduction of at least 2 percent, 3 percent, 5 percent, or in some cases even 10 percent or more. These subsequent forming passes continue to close up the centerline porosity and further densify the preform, while also beginning to shape the preform closer to the final desired shape of the metallic article.

[0044] In some instances, the method can include additional forming passes that progressively reduce the cross-sectional area. For example, a second subsequent forming pass can reduce the further-decreased cross-sectional area of the preform by at least 6 percent, or in another example, at least 10 percent. Each of these passes serves to further refine and shape the preform, enhancing densification and improving the microstructure and mechanical properties of the final product.

[0045] This staged, progressive approach to the cogging process allows for a controlled and efficient method of transforming the preform into the final metallic article, minimizing the risk of damage or fracture to the preform, and enhancing the properties and quality of the final product.

[0046] In an example, the step of reducing the cross-sectional area of the preform via at least one forming pass of a cogging process may include: reducing the cross-sectional area of the preform via an initial forming pass of a cogging process so that the preform has a decreased cross-sectional area; and reducing the decreased cross-sectional area of the preform via a subsequent forming pass of the cogging process by a greater percentage than that, by which the cross-sectional area of the preform was reduced during the initial forming pass. The amount/magnitude by which the initial forming pass of the cogging process reduces the cross-sectional area of the preform may be sufficient to close centerline porosity of the preform without damaging the preform.

[0047] In an example, the initial forming pass of the cogging process may reduce the cross-sectional area of the preform by at most 2 percent. In another example, the initial forming pass of the cogging process may reduce the cross-sectional area of the preform by at most 1.5 percent. In another example, the initial forming pass of the cogging process may reduce the cross-sectional area of the preform by at most 1 percent.

[0048] In an example, the subsequent forming pass of the cogging process may reduce the decreased cross-sectional area of the preform by at least 2 percent. In another example, the subsequent forming pass of the cogging process may reduce the decreased cross-sectional area of the preform by at least 3 percent. In another example, the subsequent forming pass of the cogging process may reduce the decreased cross-sectional area of the preform by at least 5 percent. In another example, the subsequent forming pass of the cogging process may reduce the decreased cross-sectional area of the preform by at least 10 percent.

[0049] In a specific example, the subsequent forming pass of the cogging process reduces the decreased cross-sectional area of the preform by at least 3 percent so that the preform has a further-decreased cross-sectional area, and a second subsequent forming pass of the cogging process reduces the further-decreased cross-sectional area of the preform by at least 6 percent.

[0050] In another specific example, the subsequent forming pass of the cogging process reduces the decreased cross-sectional area of the preform by at least 5 percent so that the preform has a further-decreased cross-sectional area, and a second subsequent forming pass of the cogging process reduces the further-decreased cross-sectional area of the preform by at least 10 percent.

[0051] The cogging process is performed at a temperature conducive to effective and efficient deformation. This temperature, known as the cogging-process temperature, is selected taking into account several factors, including the type of metallic powder used to form the preform, the extent of deformation desired, and the planned sequence of forming operations.

[0052] The cogging-process temperature is chosen relative to the solidus temperature of the metallic powder composition. This is done to ensure that the preform remains in a solid state during the cogging process, while still being sufficiently malleable for effective deformation. The elevated temperature also aids in the densification process and assists in the closure of porosity.

[0053] In general, the cogging-process temperature may typically be at most 95 percent of the solidus temperature (in degrees Kelvin) of the metallic powder composition. This ensures the preform remains solid and workable without melting. However, the cogging-process temperature could be set within a range lower than this maximum, based on the specific requirements of the cogging process and the final metallic article.

[0054] For instance, the cogging-process temperature may be within a range of 60 percent to 90 percent of the solidus temperature of the metallic powder composition. Alternatively, for some metallic powders, it may be more suitable for the cogging-process temperature to be within a range of 40 percent to 60 percent, or even 20 percent to 40 percent, of the solidus temperature.

[0055] In some cases, it could be beneficial for the cogging-process temperature to be quite low, at most 20 percent of the solidus temperature of the metallic powder composition. Such a low temperature could be useful when working with certain metallic powders that have high solidus temperatures or when the cogging process aims to impose a cold deformation on the preform.

[0056] In all these cases, the specific cogging-process temperature chosen is tailored to the metallic powder composition, the desired preform characteristics, and the specific requirements of the final metallic article. The goal is to ensure efficient and effective densification and deformation, while minimizing any risk of damaging or melting the preform.

[0057] In an example, the cogging-process temperature is at most 95 percent of a solidus temperature (in degrees Kelvin) of the metallic powder composition. In another example, the cogging-process temperature is in a temperature range of 60 percent to 90 percent of the solidus temperature (in degrees Kelvin) of the metallic powder composition. In another example, the cogging-process temperature is in a temperature range of 40 percent to 60 percent of the solidus temperature (in degrees Kelvin) of the metallic powder composition. In another example, the cogging-process temperature is in a temperature range of 20 percent to 40 percent of the solidus temperature (in degrees Kelvin) of the metallic powder composition. In another example, the cogging-process temperature is at most 20 percent of a solidus temperature (in degrees Kelvin) of the metallic powder composition.

[0058] The effectiveness and efficiency of the cogging process can be further controlled through adjustment of the cogging-process average equivalent strain rate. The cogging-process average equivalent strain rate is a parameter in forging operations, significantly influencing the material behavior, including the rate of densification, microstructure evolution, and the final properties of the metallic article.

[0059] In the described method, the cogging process can be performed at a variety of strain rates, with the specific rate chosen depending on the characteristics of the metallic powder composition and the desired properties of the final metallic article. This strain rate could range from as low as 0.00001 s-1 up to 100 s-1. This range covers a broad spectrum of deformation speeds, from quasi-static conditions to very rapid deformation.

[0060] For certain metallic powders and preform conditions, lower strain rates may be preferred. As such, the cogging process could be performed at an average equivalent strain rate ranging from 0.00001 s-1 to 0.01 s-1. Lower strain rates may allow for more controlled deformation, potentially reducing the risk of damage to the preform.

[0061] Alternatively, for other metallic powders or when faster deformation is desirable, the cogging-process average equivalent strain rate may be set to range from 0.01 s-1 to 1 s-1, or in some cases, from 1 s-1 to 100 s-1. Higher strain rates can allow for quicker deformation, potentially increasing the efficiency of the cogging process.

[0062] By selecting the strain rate, the cogging process can be optimized to maximize the densification, enhance the microstructure, and improve the mechanical properties of the final metallic article, while also ensuring the efficiency of the process.

[0063] In an example, the step of reducing the cross-sectional area of the preform via the at least one forming pass of a cogging process is performed at a cogging-process average equivalent strain rate that ranges from 0.00001 s.sup.1 to 100 s.sup.1.

[0064] In another example, the step of reducing the cross-sectional area of the preform via the at least one forming pass of a cogging process is performed at a cogging-process average equivalent strain rate that ranges from 0.00001 s.sup.1 to 0.01 s.sup.1.

[0065] In another example, the step of reducing the cross-sectional area of the preform via the at least one forming pass of a cogging process is performed at a cogging-process average equivalent strain rate that ranges from 0.01 s.sup.1 to 1 s.sup.1.

[0066] In another example, the step of reducing the cross-sectional area of the preform via the at least one forming pass of a cogging process is performed at a cogging-process average equivalent strain rate that ranges from 1 s.sup.1 to 100 s.sup.1.

[0067] Annealing, a heat treatment process, can also play a significant role in the method. Annealing involves heating the preform to a specific temperature, holding it at this temperature for a certain duration, and then allowing it to cool down. This heat treatment can serve multiple purposes, including relieving the stresses induced during the cogging process, promoting further densification, and refining the microstructure of the preform, depending on the type of metallic material.

[0068] The annealing process can be performed at various stages during the method, depending on the specific requirements of the metallic article. It can be carried out prior to the cogging process, serving as a preparatory step that conditions the preform for the subsequent deformation. This initial annealing can improve the ductility of the metallic powder composition, making it more amenable to the upcoming cogging process.

[0069] Annealing can also be applied intermediate to the cogging process. Between forming passes, the preform can be annealed to relieve the deformation-induced stresses. This intermediate annealing can prevent the build-up of excessive internal stresses, which could potentially lead to cracking or other forms of damage in the preform. Furthermore, by refining the microstructure between passes, intermediate annealing can promote more uniform densification and improve the mechanical properties of the final metallic article.

[0070] Post-cogging annealing can be carried out. Once the cogging process is complete, the preform can be annealed to relieve any remaining stresses.

[0071] The specific annealing conditions, such as the temperature, duration, and cooling rate, can be tailored based on the nature of the metallic powder, the specific stage of the method, and the desired properties of the final product.

[0072] Rotary incremental forming is another versatile operation that may involve several sub-processes such as rotary swaging, rotary pilgering, rotary piercing, or trepanning. These processes can be classified under the broader scope of rotary incremental forming. The key principle behind all these processes is the application of a localized deformation to the preform, further reducing its cross-sectional area and enhancing its densification. Rotary swaging, for instance, is a method where the preform is rotated and compressed by a set of reciprocating dies, reducing its diameter and improving the grain structure. This process can result in a finished piece with enhanced mechanical properties and reduced surface porosity. Rotary pilgering is typically employed to reduce the diameter and wall thickness of tubular preforms. The preform is rotated and reciprocated over a mandrel while being worked by a pair of oblique-angled dies. The combined rotary and reciprocating motion imparts incremental deformation which can effectively reduce surface porosity, refining the structure of the preform. Rotary piercing is a process where the preform is subjected to a combined rotary and forward motion, while being internally deformed by a piercing mandrel and externally by a set of rollers. Trepanning is a process in which a preform is rotated and a drill or cutting tool is used to remove material in a circular path, creating deep holes or cavities within the preform. This process may be utilized in conjunction with other rotary incremental forming operations for creating complex geometries within the metallic article. Each of these rotary incremental forming processes allows for controlled deformation of the preform, further reducing its cross-sectional area and promoting densification. They also contribute to refining the microstructure and reducing surface porosity, both of which enhance the properties of the final metallic article. The choice between rotary swaging, pilgering, piercing, and trepanning will depend on the desired final shape and size of the metallic article, as well as the specific properties of the metallic powder composition.

[0073] In the process of reducing the cross-sectional area of the preform via the rotary incremental forming process, the approach may be staged or progressive, involving multiple forming passes each reducing the cross-sectional area by a different degree.

[0074] The cross-sectional area of the preform may be reduced via an initial forming pass of the rotary incremental forming process that results in a modest reduction of the cross-sectional area. This initial pass can often be considered a softening or conditioning stage, where the preform is prepared for more significant deformation in subsequent stages. This initial pass does not significantly alter the dimensions of the preform, perhaps reducing the cross-sectional area by no more than 2 percent, 1.5 percent, or even as little as 1 percent. Despite this modest dimensional change, the initial forming pass plays a role in initiating the closure of surface porosity in the preform, without damaging or fracturing the preform.

[0075] After the initial forming pass, further reduction of the decreased cross-sectional area of the preform is achieved via one or more subsequent forming passes of the rotary incremental forming process. The subsequent pass reduces the cross-sectional area by a greater percentage than the initial forming pass. This could be a reduction of at least 2 percent, 3 percent, 5 percent, or in some cases even 10 percent or more. These subsequent forming passes continue to close up the surface porosity and further densify the preform, while also beginning to shape the preform closer to the final desired shape of the metallic article.

[0076] In some instances, the method can include additional forming passes that progressively reduce the cross-sectional area. For example, a second subsequent forming pass can reduce the further-decreased cross-sectional area of the preform by at least 6 percent, or in another example, at least 10 percent. Each of these passes serves to further refine and shape the preform, enhancing densification and improving the microstructure and mechanical properties of the final product.

[0077] This staged, progressive approach to the rotary incremental forming process allows for a controlled and efficient method of transforming the preform into the final metallic article, minimizing the risk of damage or fracture to the preform, and enhancing the properties and quality of the final product.

[0078] In an example, the step of reducing the cross-sectional area of the preform via at least one forming pass of a rotary incremental forming process includes: reducing the cross-sectional area of the preform via an initial forming pass of a rotary incremental forming process so that the preform has a decreased cross-sectional area; and reducing the decreased cross-sectional area of the preform via a subsequent forming pass of the rotary incremental forming process by a greater percentage than that, by which the cross-sectional area of the preform was reduced during the initial forming pass. The amount/magnitude by which the initial forming pass of the rotary incremental forming process reduces the cross-sectional area of the preform may be sufficient to close surface porosity of the preform without damaging the preform.

[0079] In an example, the initial forming pass of the rotary incremental forming process reduces the cross-sectional area of the preform by at most 2 percent. In another example, the initial forming pass of the rotary incremental forming process reduces the cross-sectional area of the preform by at most 1.5 percent. In another example, the initial forming pass of the rotary incremental forming process reduces the cross-sectional area of the preform by at most 1 percent.

[0080] In an example, the subsequent forming pass of the rotary incremental forming process reduces the decreased cross-sectional area of the preform by at least 2 percent. In another example, the subsequent forming pass of the rotary incremental forming process reduces the decreased cross-sectional area of the preform by at least 3 percent. In another example, the subsequent forming pass of the rotary incremental forming process reduces the decreased cross-sectional area of the preform by at least 5 percent. In another example, the subsequent forming pass of the rotary incremental forming process reduces the decreased cross-sectional area of the preform by at least 10 percent.

[0081] In a specific example, the subsequent forming pass of the rotary incremental forming process reduces the decreased cross-sectional area of the preform by at least 3 percent so that the preform has a further-decreased cross-sectional area, and a second subsequent forming pass of the rotary incremental forming process reduces the further-decreased cross-sectional area of the preform by at least 6 percent.

[0082] In a specific example, the subsequent forming pass of the rotary incremental forming process reduces the decreased cross-sectional area of the preform by at least 5 percent so that the preform has a further-decreased cross-sectional area, and a second subsequent forming pass of the rotary incremental forming process reduces the further-decreased cross-sectional area of the preform by at least 10 percent.

[0083] The rotary incremental forming process, like the process, can be performed at different temperatures. The temperature during this process, which we refer to as the rotary incremental forming-process temperature, is selected based on a variety of factors, including the material properties of the metallic powder composition, the amount/magnitude of reduction in cross-sectional area, and whether intermediate annealing steps are included in the process.

[0084] In one example, the rotary incremental forming-process temperature is at most 95 percent of the solidus temperature of the metallic powder composition, measured in degrees Kelvin. The exact temperature within this range can be selected based on the specific requirements of the process and the desired properties of the final metallic article. For example, in certain cases, the rotary incremental forming-process temperature may be in a range of 60 percent to 90 percent of the solidus temperature of the metallic powder composition. In other cases, it may be in a range of 40 percent to 60 percent, or 20 percent to 40 percent. In certain examples, the rotary incremental forming-process temperature could be at most 20 percent of the solidus temperature of the metallic powder composition.

[0085] The rotary incremental forming process is also influenced by the average equivalent strain rate applied during the process. The average equivalent strain rate can vary over a wide range, from as low as 0.00001 s-1 to as high as 100 s-1, depending on factors such as the material properties of the metallic powder composition and the specifics of the forming process. In certain examples, the rotary incremental forming process may be performed at an average equivalent strain rate ranging from 0.00001 s-1 to 0.01 s-1, from 0.01 s-1 to 1 s-1, or from 1 s-1 to 100 s-1. The choice of strain rate can affect factors such as the rate of reduction of the cross-sectional area, the quantity of heat generated during the process, and the properties of the final metallic article.

[0086] As with the cogging process, annealing may also be incorporated into the rotary incremental forming process. Annealing can be performed before, after, or in between the forming passes of the rotary incremental forming process. This annealing process, which involves heating the preform to a specific temperature and then slowly cooling it, can help to relieve stresses in the preform, enhance the material's ductility, and improve the material's response to subsequent deformation. The specifics of the annealing process, such as the annealing temperature and the duration of the annealing step, can be tailored based on the material properties of the metallic powder composition and the requirements of the forming process.

[0087] In one example, the method may include a step of annealing the preform between the cogging process and the rotary incremental forming process. This annealing step can help to prepare the preform for the deformation that will occur during the subsequent forming process, improving the ductility of the material and reducing the risk of fracture or damage during the process.

[0088] In another example, the method may include one or more intermediate annealing steps that are performed in between forming passes of the rotary incremental forming process. These intermediate annealing steps can help to relieve stresses that are induced in the preform during the forming process, preventing the buildup of excessive stress and reducing the risk of fracture or damage.

[0089] In yet another example, the method may include a step of annealing the preform after the rotary incremental forming process. This post-forming annealing step can help to relieve any residual stresses in the preform and improve the properties of the final metallic article.

[0090] In any of these examples, the annealing step may involve heating the preform to an annealing temperature that is less than the solidus temperature of the metallic powder composition, maintaining the preform at the annealing temperature for a specified duration, and then cooling the preform at a controlled rate. The specifics of the annealing process, including the annealing temperature, the duration of the annealing step, and the cooling rate, can be tailored based on the material properties of the metallic powder composition and the requirements of the forming process.

[0091] In certain examples of the method, an additional feature could be implemented, wherein the rotary incremental forming process is performed before the cogging process. This pre-cogging rotary incremental forming process serves to close the surface porosity of the preform, thereby mitigating the risk of surface tearing during the cogging process, which may occur under certain conditions such as specific material types, temperatures, strain rates, and porosity contents. After the pre-cogging rotary incremental forming process has been conducted to reduce surface porosity, the cogging process is performed. This step, as previously described, involves reducing the cross-sectional area of the preform and helps to further decrease centerline porosity. Subsequently, the rotary incremental forming process is performed again, continuing to reduce the cross-sectional area and further refine the surface of the cogged preform.

[0092] The pre-cogging rotary incremental forming process can incorporate any or all features of the post-cogging rotary incremental forming process previously described, depending on the specific requirements of the metallic article being manufactured. Such a sequence of operations provides flexibility in the manufacturing process while ensuring the production of a high-quality, fully dense wrought metallic article with minimal surface porosity and tearing. This sequence of processesthe pre-cogging rotary incremental forming process, the cogging process, and the post-cogging rotary incremental forming processoffers a controlled, efficient method for shaping the preform into a final metallic article. It reduces the risk of surface damage or fracture to the preform, while enhancing the properties and quality of the final product.

[0093] The article may go through additional post-processing, which may include various operations to enhance the quality and performance of the final product. For example, post-processing may involve a final heat treatment, which can be applied to the wrought metallic articles that have been consolidated, heat treated, and then thermo-mechanically processed by the method described above. The final heat treatment can adjust the mechanical properties, microstructure, and residual stresses of the material, depending on the desired outcome. Post-processing may also include grinding, machining, or other surface treatments to remove any defects, irregularities, or excess material from the surface of the aircraft or its components. These processes can improve the dimensional accuracy, surface finish, and corrosion resistance of the product. Additionally, post-processing may involve applying protective coatings, paints, or other substances to the surface of the article, which can enhance the aesthetic appeal, durability, and functionality of the product.

[0094] The present description is further directed to a wrought metallic article, as produced by the method described above, embodies a number of advantageous characteristics. These advantages arise from the distinctive aspects of the method, which includes a sequenced series of processing steps, including consolidation of the metallic powder composition, applying a supersolidus heat treatment, and thermo-mechanical processing. This method enables the production of a wrought metallic article with excellent mechanical properties, such as high strength, ductility, and toughness. Further, the application of the supersolidus heat treatment enables for mitigation of prior particle boundaries, and the application of thermo-mechanical processing such as the cogging and rotary incremental forming processes provides thorough densification of the material and refines its microstructure, contributing to the superior mechanical performance of the final product. The method also leads to the creation of a metallic article with reduced porosity. The specific sequences of deformation in the cogging and rotary incremental forming processes, including the controlled reduction of cross-sectional areas, aids in eliminating both centerline and surface porosity in the preform. This reduction in porosity not only improves the mechanical properties of the wrought article but also enhances its corrosion resistance and surface finish. The wrought metallic article also has a uniform and controlled grain structure, which is a result of the specific forming and possible annealing conditions utilized in the method. This grain structure can be tailored to the requirements of specific applications, making the wrought metallic article highly versatile for various industrial uses. Overall, the wrought metallic article produced according to the described method exhibits a combination of superior mechanical properties, reduced porosity, enhanced surface finish, and a tailored grain structure. This makes it suitable for a variety of applications, including, but not limited to, aerospace, automotive, construction, and other industrial applications where high performance under demanding conditions is required.

[0095] Examples of the subject matter disclosed herein may be described in the context of aircraft manufacturing and service method 1100 as shown in FIG. 2 and aircraft 1102 as shown in FIG. 3. During pre-production, illustrative method 1100 may include specification and design (block 1104) of aircraft 1102 and material procurement (block 1106). During production, component and subassembly manufacturing (block 1108) and system integration (block 1110) of aircraft 1102 may take place. Thereafter, aircraft 1102 may go through certification and delivery (block 1112) to be placed in service (block 1114). While in service, aircraft 1102 may be scheduled for routine maintenance and service (block 1116). Routine maintenance and service may include modification, reconfiguration, refurbishment, etc., of one or more systems of aircraft 1102.

[0096] Each of the processes of illustrative method 1100 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.

[0097] As shown in FIG. 3, aircraft 1102 produced by illustrative method 1100 may include airframe 1118 with a plurality of high-level systems 1120 and interior 1122. Examples of high-level systems 1120 include one or more of propulsion system 1124, electrical system 1126, hydraulic system 1128, and environmental system 1130. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Accordingly, in addition to aircraft 1102, the principles disclosed herein may apply to other vehicles, e.g., land vehicles, marine vehicles, space vehicles, etc.

[0098] Apparatus(es) and method(s) shown or described herein may be employed during any one or more of the stages of the manufacturing and service method 1100. For example, components or subassemblies corresponding to component and subassembly manufacturing (block 1108) may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft 1102 is in service (block 1114). Also, one or more examples of the apparatus(es), method(s), or combination thereof may be utilized during production stages (block 1108 and block 1110), for example, by substantially expediting assembly of or reducing the cost of aircraft 1102. Similarly, one or more examples of the apparatus or method realizations, or a combination thereof, may be utilized, for example and without limitation, while aircraft 1102 is in service (block 1114) and/or during maintenance and service (block 1116).

[0099] Further, the disclosure comprise examples according to the following clauses:

[0100] Clause 1. A method for manufacturing an article, the method comprising: consolidating a metallic powder composition into a consolidated preform; applying a supersolidus heat treatment to the consolidated preform during or after consolidating the metallic powder composition to yield a heat treated preform; and reducing a cross-sectional area of the heat treated preform by thermo-mechanical processing to yield a processed preform.

[0101] Clause 2. The method of Clause 1, wherein the metallic powder composition comprises at least one of an alloy, an intermetallic, and a metal-matrix composite.

[0102] Clause 3. The method of Clause 1, wherein the metallic powder composition comprises at least one of an aluminum alloy, a metal-matrix composite comprising aluminum, a titanium alloy, a metal-matrix composite comprising titanium, a superalloy, an iron alloy, a metal-matrix composite comprising iron, a nickel alloy, a metal-matrix composite comprising nickel, a cobalt alloy, a metal-matrix composite comprising cobalt, a refractory metal alloy, a metal-matrix composite comprising a refractory metal, a copper alloy, a metal-matrix composite comprising copper, a precious-metal alloy, a metal-matrix composite comprising a precious metal, a zirconium alloy, a metal-matrix composite comprising zirconium, a hafnium alloy, a metal-matrix composite comprising hafnium, a rare-earth-metal alloy, a metal-matrix composite comprising a rare-earth metal, a magnesium alloy, a metal-matrix composite comprising magnesium, a steel, a metal-matrix composite comprising steel, an intermetallic, a complex concentrated alloy, a metal-matrix composite comprising a complex concentrated alloy, a high-entropy alloy, a metal-matrix composite comprising a high-entropy alloy, a medium-entropy alloy, a metal-matrix composite comprising a medium-entropy alloy, a multicomponent alloy, and a metal-matrix composite comprising a multicomponent alloy.

[0103] Clause 4. The method of Clause 1, wherein the metallic powder composition comprises a nickel alloy.

[0104] Clause 5. The method of Clause 1, wherein the metallic powder composition comprises at least one of granular particles, spherical particles, spheroidal particles, fines, chips, or flakes.

[0105] Clause 6. The method of Clause 1, wherein the metallic powder composition comprises a blend of a first metallic powder component having a first composition with a second metallic powder component having a second composition to yield the metallic powder composition.

[0106] Clause 7. The method of Clause 1, wherein consolidating the metallic powder composition comprises pressing the metallic powder composition.

[0107] Clause 8. The method of Clause 1, wherein consolidating the metallic powder composition comprises isostatic pressing the metallic powder composition.

[0108] Clause 9. The method of Clause 1, wherein consolidating the metallic powder composition comprises hot pressing the metallic powder composition.

[0109] Clause 10. The method of Clause 1, wherein consolidating the metallic powder composition comprises hot isostatic pressing the metallic powder composition.

[0110] Clause 11. The method of Clause 1, wherein consolidating the metallic powder composition comprises vacuum hot pressing the metallic powder composition.

[0111] Clause 12. The method of Clause 1, wherein consolidating the metallic powder composition comprises cold pressing the metallic powder composition.

[0112] Clause 13. The method of Clause 1, wherein consolidating the metallic powder composition comprises cold isostatic pressing the metallic powder composition.

[0113] Clause 14. The method of Clause 1, wherein consolidating the metallic powder composition comprises sintering the metallic powder composition.

[0114] Clause 15. The method of Clause 1, wherein consolidating the metallic powder composition comprises cold isostatic pressing and sintering the metallic powder composition.

[0115] Clause 16. The method of Clause 1, wherein consolidating the metallic powder composition comprises sintering the metallic powder composition.

[0116] Clause 17. The method of Clause 1, wherein consolidating the metallic powder composition comprises spark plasma sintering the metallic powder composition.

[0117] Clause 18. The method of Clause 1, wherein consolidating the metallic powder composition comprises high strain rate densification.

[0118] Clause 19. The method of Clause 1, wherein the supersolidus heat treatment is applied during the consolidating of the metallic powder composition into the consolidated preform.

[0119] Clause 20. The method of Clause 1, wherein consolidating the metallic powder composition is performed at a temperature above a supersolidus temperature of the metallic powder composition.

[0120] Clause 21. The method of Clause 1, wherein consolidating the metallic powder composition is performed at a temperature below a supersolidus temperature of the metallic powder composition.

[0121] Clause 22. The method of Clause 1, wherein consolidating the metallic powder composition comprises hot isostatic pressing the metallic powder composition at a temperature above a supersolidus temperature of the metallic powder composition.

[0122] Clause 23. The method of Clause 1, wherein the supersolidus heat treatment is applied after consolidating the metallic powder composition into the consolidated preform.

[0123] Clause 24. The method of Clause 1, wherein consolidating the metallic powder composition results in formation of prior particle boundaries in the consolidated preform.

[0124] Clause 25. The method of Clause 24, wherein the supersolidus heat treatment is applied after consolidating the metallic powder composition into the consolidated preform.

[0125] Clause 26. The method of Clause 1, wherein consolidating the metallic powder composition results in formation of prior particle boundaries in the consolidated preform, and wherein the supersolidus heat treatment eliminates at least a portion of the prior particle boundaries.

[0126] Clause 27. The method of Clause 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 99.9 percent.

[0127] Clause 28. The method of Clause 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 99.5 percent.

[0128] Clause 29. The method of Clause 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 99 percent.

[0129] Clause 30. The method of Clause 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 98 percent.

[0130] Clause 31. The method of Clause 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 97 percent.

[0131] Clause 32. The method of Clause 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 96 percent.

[0132] Clause 33. The method of Clause 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 95 percent.

[0133] Clause 34. The method of Clause 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 90 percent.

[0134] Clause 35. The method of Clause 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 85 percent.

[0135] Clause 36. The method of Clause 1, wherein, following the supersolidus heat treatment, a relative density of the heat treated preform is at most 80 percent.

[0136] Clause 37. The method of Clause 1, wherein the thermo-mechanical processing comprises a cogging process.

[0137] Clause 38. The method of Clause 37, wherein the cogging process comprises an open die forging process.

[0138] Clause 39. The method of Clause 37, wherein the cogging process comprises upsetting.

[0139] Clause 40. The method of Clause 37, wherein the cogging process comprises pancaking.

[0140] Clause 41. The method of Clause 37, wherein the cogging process comprises billeting.

[0141] Clause 42. The method of Clause 1, wherein the thermo-mechanical processing comprises a rotary incremental forming process.

[0142] Clause 43. The method of Clause 42, wherein the rotary incremental forming process comprises a rotary swaging process.

[0143] Clause 44. The method of Clause 42, wherein the rotary incremental forming process comprises a rotary pilgering process.

[0144] Clause 45. The method of Clause 42, wherein the rotary incremental forming process comprises a rotary piercing process.

[0145] Clause 46. The method of Clause 42, wherein the rotary incremental forming process comprises trepanning.

[0146] Clause 47. The method of Clause 1, wherein the thermo-mechanical processing comprises: reducing the cross-sectional area of the heat treated preform via an initial forming pass so that the heat treated preform has a decreased cross-sectional area; and reducing the decreased cross-sectional area of the heat treated preform via a subsequent forming pass by a greater percentage than that, by which the cross-sectional area of the heat treated preform was reduced during the initial forming pass.

[0147] Clause 48. The method of Clause 47, wherein the initial forming pass reduces the cross-sectional area of the heat treated preform by at most 2 percent.

[0148] Clause 49. The method of Clause 47, wherein the initial forming pass reduces the cross-sectional area of the heat treated preform by at most 1.5 percent.

[0149] Clause 50. The method of Clause 47, wherein the initial forming pass reduces the cross-sectional area of the heat treated preform by at most 1 percent.

[0150] Clause 51. The method of Clause 47, wherein the subsequent forming pass reduces the decreased cross-sectional area of the heat treated preform by at least 2 percent.

[0151] Clause 52. The method of Clause 47, wherein the subsequent forming pass reduces the decreased cross-sectional area of the heat treated preform by at least 3 percent.

[0152] Clause 53. The method of Clause 47, wherein the subsequent forming pass reduces the decreased cross-sectional area of the heat treated preform by at least 5 percent.

[0153] Clause 54. The method of Clause 47, wherein the subsequent forming pass reduces the decreased cross-sectional area of the heat treated preform by at least 10 percent.

[0154] Clause 55. The method of Clause 1, wherein the thermo-mechanical processing is performed at a temperature (in degrees Kelvin) that is at most 95 percent of a solidus temperature (in degrees Kelvin) of the metallic powder composition.

[0155] Clause 56. The method of Clause 1, wherein the thermo-mechanical processing is performed at a temperature (in degrees Kelvin) that is in a temperature range of 60 percent to 90 percent of a solidus temperature (in degrees Kelvin) of the metallic powder composition.

[0156] Clause 57. The method of Clause 1, wherein the thermo-mechanical processing is performed at a temperature (in degrees Kelvin) that is in a temperature range of 40 percent to 60 percent of a solidus temperature (in degrees Kelvin) of the metallic powder composition.

[0157] Clause 58. The method of Clause 1, wherein the thermo-mechanical processing is performed at a temperature (in degrees Kelvin) that is in a temperature range of 20 percent to 40 percent of a solidus temperature (in degrees Kelvin) of the metallic powder composition.

[0158] Clause 59. The method of Clause 1, wherein the thermo-mechanical processing is performed at a temperature (in degrees Kelvin) that is at most 20 percent of a solidus temperature (in degrees Kelvin) of the metallic powder composition.

[0159] Clause 60. The method of Clause 1, wherein the thermo-mechanical processing is performed at an average equivalent strain rate that ranges from 0.00001 s-1 to 100 s-1.

[0160] Clause 61. The method of Clause 1, wherein the thermo-mechanical processing is performed at an average equivalent strain rate that ranges from 0.00001 s-1 to 0.01 s-1.

[0161] Clause 62. The method of Clause 1, wherein the thermo-mechanical processing is performed at an average equivalent strain rate that ranges from 0.01 s-1 to 1 s-1.

[0162] Clause 63. The method of Clause 1, wherein the thermo-mechanical processing is performed at an average equivalent strain rate that ranges from 1 s-1 to 100 s-1.

[0163] Clause 64. The method of Clause 1, wherein the thermo-mechanical processing reduces a porosity of the heat treated preform.

[0164] Clause 65. The method of Clause 1, further comprising a step of annealing the heat treated preform before the thermo-mechanical processing.

[0165] Clause 66. The method of Clause 1, further comprising a step of annealing the heat treated preform intermediate to the thermo-mechanical processing.

[0166] Clause 67. The method of Clause 1, further comprising a step of annealing the heat treated preform after the thermo-mechanical processing.

[0167] Clause 68. The method of Clause 1, further comprising shaping the processed preform to a final shape after the thermo-mechanical processing.

[0168] Clause 69. The method of Clause 1, further comprising machining the processed preform after the thermo-mechanical processing.

[0169] Clause 70. The method of Clause 1, further comprising surface treating the processed preform after the thermo-mechanical processing.

[0170] Clause 71. The method of Clause 1, further comprising applying a final heat treatment to the processed preform after the thermo-mechanical processing.

[0171] Clause 72. A method for manufacturing an article, the method comprising: consolidating a metallic powder composition into a consolidated preform; applying a supersolidus heat treatment to the consolidated preform during or after consolidating the metallic powder composition to yield a heat treated preform; and reducing a cross-sectional area of the heat treated preform by at least one of a cogging process and a rotary incremental forming process to yield a processed preform.

[0172] Clause 73. The method of Clause 72, wherein the cross-sectional area of the heat treated preform is reduced by the cogging process and the rotary incremental forming process.

[0173] Clause 74. The method of Clause 73, wherein the cogging process is performed before the rotary incremental forming process.

[0174] Clause 75. The method of Clause 73, wherein the rotary incremental forming process is performed before the cogging process.

[0175] Clause 76. The method of Clause 73, wherein the rotary incremental forming process is performed before the cogging process and after the cogging process.

[0176] Clause 77. A wrought metallic article manufactured according to a method comprising: consolidating a metallic powder composition into a consolidated preform; applying a supersolidus heat treatment to the consolidated preform during or after consolidating the metallic powder composition to yield a heat treated preform; and reducing a cross-sectional area of the heat treated preform by thermo-mechanical processing.

[0177] Although various embodiments of the disclosed methods have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.