Wyman-Gordon Process flow diagram:
I) Wyman Gordon purchases cylinders of Nickel/Titanium raw material. The material cost for a single turbine disk is roughly $50,000.
II) Then a piece of the stock cylinder is cut to make the turbine disk.
III) The Molybdenum die is polished and cleaned prior to heating. Each die set can cost between $250,000 to $1,000,000
IV) Both the raw material and the die set are put in an electric furnace. The temperature of the raw material is raised above the recrystallization temperature. The temperature of the molydemum die is raised to match the temperature of the material. Thermocouples are used to control the temperature of the furnace.
V) When the part and die are at necessary temperature, the die is intalled into the press and then the part is placed in between the die.
VI) A vacuum is pulled in the forge.
VII) The die is then pressed into the part at a slow rate until the desired shape is achieved.
VIII) The part is then removed from the forge and measured to ensure the part is within tolerance. For Wyman-Gordon's Worcester facility, the tolerance they need to hold the parts to is 1/8".
IX) Machine off outer layer of residue on part produced during forging.
X) Test part for internal cracks using a sonic testing bath.
XI) The part is then polished and cleaned and prepared for shipping.