DESC:TECHNICAL FIELD
[0001] The present disclosure relates generally to the technical field of hot forging. More particularly, the present disclosure relates to production of Waspaloy components especially ring shaped components using the hot forging method.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.
[0003] Waspaloy is a precipitation-hardened nickel-based super alloy with excellent high-temperature strength, good corrosion resistance, high resistance to creep fatigue, and excellent isothermal oxidation resistance for operating temperature up to 700 ?. The high-temperature strength of the Waspaloy is derived from its solid solution-strengthening elements, chromium (Cr), cobalt (Co), and molybdenum (Mo), and its precipitation-hardening elements such as aluminium (Al), and titanium (Ti). It is suitable for applications that require considerable strength and corrosion resistance at high operating temperatures, and is commonly used for manufacturing aero engine key components such as compressor, rotor discs, shafts, spacers, seals, rings and casings, aircraft assemblies, missile systems, etc.
[0004] However, forging of Waspaloy is difficult because of its low ductility and high resistance to deformation at elevated temperatures. Further, selecting optimal parameters for processing the Waspaloy using forging method is a critical task. The main issue while Waspaloy forging at low deformation temperatures is related with fine ‘?’ Precipitates, that makes alloy too stiff to process by increasing forging loads. This leads to inhomogeneous deformation, and flow instability in the form of shear bands. Further, a high temperature deformation is accompanied by rapid grain growth, hot shortness and cracking. Forming articles from crack susceptible alloys can be problematic, for example, cracks formed during forging or other hot working operations may need to be ground or otherwise removed, increasing manufacturing time and costs and increasing material yield. Being a thermally dominated process, if done incorrectly, it can lead to surface damage and higher chances of component rejection.
[0005] In view of the above drawbacks, it would be advantageous to provide a more effective and / or more cost effective hot forging method for crack, susceptible alloy. More particularly, it would be advantageous to provide a method for improving hot workability of alloy.
[0006] Patent document CN114309382A discloses a precision rolling forming method for Waspaloy alloy large-scale case forging including steps of special pre-rolling, special-shaped finish rolling and special-shaped bulging adopted, and a pre-rolling core roller with a smaller size is designated, so that the rolling deformation is ensured; the rolling stability of the blank in the finish rolling process is ensured by the finish rolling core roller with larger size; meanwhile, the special-shaped bulging process is combined, the precision of the forging, material utilization rate is improved, and the manufactured Waspaloy alloy large-scale case forging meets the design requirements.
[0007] Another Patent document KR102013979B1 discloses methods to improve hot workability of metal alloys where steps of alloy ingots and other alloy workpieces to reduce thermal cracking may include spraying a metal coating material onto at least a portion of surface of the alloy workpiece to form a surface coating that is metallurgically bonded to the alloy workpiece. The surface can be softer than the alloy work piece and reduce heat loss from the alloy workpiece.
[0008] Although the cited references disclose various methods to produce pieces of Waspaloy, however, the disclosed methods are costly and having higher production time. Thus, there is a possibility of providing a more efficient solution to the stated problem by reducing process steps which can result in lower production time and cost.
[0009] There is, therefore, a need to provide a simple and cost-effective solution that can eliminate the above-mentioned problems including the unsatisfactory process economics due to inadequate load requirements, poor material yield and higher processing time.

OBJECTS OF THE PRESENT DISCLOSURE
[0010] A general object of the present disclosure is to overcome the problems associated with the existing hot forging and provide a simple, cost efficient method and a system to forge a Waspaloy alloy.
[0011] Yet another object of the present disclosure is to facilitate a hot forging method to produce a ring shaped Waspaloy component.
[0012] Yet another object of the present disclosure is to produce a ring shaped Waspaloy component in a single heat cycle in hot forging operation.

SUMMARY
[0013] Aspects of the present disclosure pertain to hot forging. In particular, the present disclosure pertains to a production of Waspaloy components especially ring shaped components using a hot forging method.
[0014] An aspect of the present disclosure pertains to a method of forging a Waspaloy alloy. The method includes cutting a raw Waspaloy alloy material for a predefined billet. The method includes first heating the predefined billet to a predefined first temperature using an electric furnace or sulphur free gas/oil fired furnace. Further, the method includes forging the heated predefined billet using a forging machine to complete the deformation of the heated predefined billet in one heat cycle forging a doughnut.
[0015] In addition, the method includes first machining the doughnut to remove flash and slug from an inner diameter and an outer diameter of the doughnut producing a machined doughnut. Furthermore, the method includes second heating of the machined doughnut using the electric furnace or sulphur free gas/oil fired furnace to the predefined first temperature. Moreover, the method includes radial ring rolling of the heated machined doughnut using a rolling machine to produce a ring. The method also includes a step of treating the ring using a heat treatment and a second machining of the treated ring for desired shape and dimension, thereby producing a final ring.
[0016] In an embodiment, the predefined billet may be a crack-free cylindrical billet.
[0017] Yet in another embodiment, the predefined first temperature may be between a temperature range of 1020 degrees Celsius to 1120 degrees Celsius.
[0018] Yet in another embodiment, the forging can be a close die forging.
[0019] Yet in another embodiment, the doughnut may define a first predefined angle, a second predefined angle, and a radius. The first predefined angle may be between a range of 5 degrees to 10 degrees. The second predefined angle may be between 45 degrees to 50 degrees. The radius may facilitate the corners of the doughnut to be smooth.
[0020] Yet in another embodiment, the first predefined angle, the second predefined angle, and the radius may facilitate the radial ring rolling to be performed with a predetermined load.
[0021] Yet in another embodiment, the forging may adopt a finite element modelling (FEM). The FEM may produce the doughnut.
[0022] Yet in another embodiment, the step of treating may be a heat treatment. The method of heat treatment may include the steps of third heating the ring at a solutionzing temperature of 955 degrees Celsius for one hour and twenty minutes. Additionally, the method may include the steps of quenching the heated ring using an oil quench. The method may further include the step of precipitation heat treatment the quenched ring at a heated at temperature of 718 degrees Celsius for eight hours. Further, the method may include the step of air cooling the heated ring to a room temperature.
[0023] In another embodiment, the rolling machine may be configured to roll the heated machined doughnut at a feed rate ranging between 3 millimetres per second to 5 millimetres per second to produce rings. The rolling machine may be selected from a group comprising a planetary rolling mill, a tandem rolling mill, a cluster mill, a sendzimir mill, and a low capacity rolling machine.
[0024] According to another aspect, the present disclosure pertains to a system of forging a Waspaloy alloy. The system includes an electric furnace or sulphur free gas/oil fired furnace. The electric furnace or sulphur free gas/oil fired furnace is configured to heat a billet. In addition, the system includes a forging machine. The forging machine is configured to forge the billet into a doughnut in a single heat cycle. Further, the system includes a rolling machine. The rolling machine is configured to perform radial ring rolling on the heated machined doughnut to produce a ring. The rolled ring is heat treated to produce a ring of desired strength and hardness. The ring is machined to achieve desired shape and dimension. The final ring is ready to put in service.

BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0026] FIG. 1 illustrates a conventional method to produce a Waspaloy’s ring shaped components using a forging process.
[0027] FIG. 2 illustrates a method for producing Waspaloy’ s ring shaped components using a forging process, in accordance with an embodiment of the present disclosure.
[0028] FIG. 3 illustrates a sectional view of a pierced blank produced during the conventional Waspaloy forging process.
[0029] FIG. 4 illustrates a sectional view of an innovative doughnut shape, in accordance with an embodiment of the present disclosure.
[0030] FIG. 5 illustrates a comparison between the pierced blank produced during the conventional Waspaloy forging process and the innovative doughnut produced during the Waspaloy forging process, in accordance with an embodiment of the present disclosure.
[0031] FIG. 6A and 6B illustrates pattern of a microstructure of the billet and the finished component respectively, in accordance with an embodiment of the present disclosure.
[0032] FIG. 7 illustrates a block diagram describing a method of Waspaloy forging, in accordance with an embodiment of the present disclosure.
[0033] FIG. 8 illustrates a block diagram describing a system for forging a waspollay alloy, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0034] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of details offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.
[0035] Embodiments explained herein relates generally to the technical field of hot forging. More particularly, the present disclosure relates to a method for production of a ring shaped components used in aerospace using Waspaloy forging starts with a rolled cylindrical billet for heat treatment. The heated billet is put to doughnut forging operation. Then forged doughnut is machined at an outer diameter and an inner diameter side to remove the flash and slug. Further, the machined doughnut is heated and transferred on radial ring rolling machine and rolled to produce ring with required dimensions. The produced ring, then undergo various treatments including heat treatments for one hours and twenty minutes followed by oil quench and then precipitation treatment for eight hours followed by air cooling, Finally, the output produced is a heat treated part which is subjected to machining operations to get a final product which is ready to be put in service.
[0036] In an aspect, the present disclosure provides a forging method which eliminates a pancake, a punching, and a piercing operations. The elimination of certain operations leads to increase in overall material yield, and reduction in the processing time and energy requirement. A close die forging method using a hammer with high strain rate for Waspaloy ring shaped components gives an innovative doughnut die design with about 25% to 40% lower load as compared to the conventional forging process.
[0037] Referring to FIG. 1, where a conventional Wasploy forging method 100 to produce a ring rolling 128 is depicted step-wise. At step 102, the includes selecting a piece of cut billet 122. The billet 122 is of nickel-based Waspaloy alloy metal rod-shaped. At step 104, the conventional method can include passing the billet 122 through a heating temperature taken between 1020ºC to 1120ºC, and thereafter, step of pancaking 106 of the hot billet 122 is carried out through a hot forging to obtain the required pancake shape 124.
[0038] After the pancaking 106 operation, step of piercing 108 on the pancake 124 is carried out through the hot forging to obtain the required inner diameter of the blank 126. The cross-section of punched and pierced blank 126 obtained is square or rectangle in shape that demands a heavy load in the subsequent radial ring rolling operations 112 and 116. Now it further passed through pierced blank heating process 110 and then for radial ring rolling operation 112. The force or load requirement for radial ring rolling 112 for expanding the diameter of the blank 126 is very high.
[0039] Further, as it has been observed that the deformability of material is also to be low which may lead to cracks during the process. Therefore, multiple heating, at least two times is required for which steps of reheating 114 are required before again going for process of radial ring rolling 116. These steps of radial ring rolling 112 and 116 and multiple heating at least two times 110 and 114 are applied on the ring to achieve the ring 128 similar to the shape and dimensions what is required. This adds in the increase in cycle time. Also, due to multiple reheating process, the grain size of the material structure coarsens, which deteriorates the subsequent mechanical properties of the alloy. Thereafter, ring 128 is processed through machining 120 process to get the ring 130 in the required shape and dimensions.
[0040] In an aspect, ring 128 of required size is going under the process of heat treatment where the temperature is kept about 955 ºC which is lower than the temperature used in the step of billet heating 104 before the pancake forging process.
[0041] Referring to FIG. 2, a method for producing Waspaloy’s ring shaped components using a forging process is disclosed. The disclosure is aimed to overcome the various drawbacks of the conventional hot forging method 100. The present disclosure relates to a production method for Waspaloy ring shaped components 130 using a close die and a ring rolling hot forging process. The key inventive feature of the disclosure is in design of doughnut shape and manufacturing process allowing production of the Waspaloy rings 128 on a ring rolling machine while maintaining low forging loads which allows use of small capacity rolling machine. The proposed method 200 consists of the hot forging process steps which includes innovative doughnut design helping to produce flow localization/crack free preform on a hammer and subsequently achieve defects free finished component with desired dimensions.
[0042] Additionally, the present disclosure eliminates few steps described in the above-mentioned conventional process 100 like a pancaking operation 106 and a piercing operation 108 and carry out the direct doughnut operation 202 followed by a radial ring rolling operation 116. The innovative doughnut design improves material yield, and expand the diameter and roll the machined heated doughnut to the required size with minimum load as well as reducing manufacturing cycle time.
[0043] The Forging of nickel-based Waspaloy is mostly difficult due to their low ductility and high resistance during deformation at rising temperatures. High flow stresses and high recrystallization temperatures make their forging temperature range narrow and thus optimization of deformation parameters like temperature, strain and strain rate becomes important.
[0044] In an embodiment, a Finite-element analysis (FEA) is used to predict the temperature distribution throughout the forged billet 122 during each stage of the forging operation. With these calculations, it is possible to design the doughnut and selecting optimum process parameters to provide the desired microstructural features.
[0045] In an embodiment, the disclosed method 200 starts with the step of cutting of raw material for a billet. According to the disclosed process, the billet 122 is made up of Waspaloy alloy preferably a cylindrical billet is selected and dimensionally checked for its shape and size. Billet 122 is also checked for presence of any other defects like cracks etc.
[0046] In an embodiment, at step 104 the billet 122 is heated to a hot forging temperature in a furnace where the hot forging temperature lies in the range between 1020º to 1120ºC. The furnace, preferably an electric furnace or sulphur free gas/oil fired furnace is used for the billet heating. Ni-based Waspaloy can be subjected to intergranular attack when heated in the presence of sulphur or sulphur compounds. Therefore, an oil furnace is avoided and the furnace atmosphere is kept sulphur free and continuously maintained in a slightly reducing condition. The output of the process step 104 is a heated billet.
[0047] In an embodiment, at step 202 of doughnut forging, the heated billet 122 is undergoing doughnut forging operation 202. The doughnut forging can be carried out in any type of forging equipment like hammer, mechanical press, screw press, hydraulic press or the like. The disclosed method 200 can use a hammer with multiple strokes required to complete the deformation in one heat cycle to obtain a doughnut 208. The flash and slug thickness can be kept optimum to improve the material yield and to reduce the processing time.
[0048] In an embodiment, at step 204, the doughnut 208 can undergo the machining process for reaching an inner diameter and an outer diameter as required for input to the final ring rolling process 116. The machining is performed on side of the inner diameter side and side of the outer diameter to remove flash and slug and thereby obtaining a machined doughnut 210. Further, at the step 206, the method can include heating of the machined doughnut to a hot forging temperature. The hot forging temperature can be maintained between a range of 1020° C to 1120° C.
[0049] In an embodiment, the heated doughnut is next transferred for a radial ring rolling 116 operations over a machine and rolled with a feed rate of 3-5 mm/s. In the proposed method 200, the innovative doughnut design makes possible to produce a ring 128 on low capacity rolling machine.
[0050] In an embodiment, at step 118, different type of treatments is given to the ring 128 under different temperatures and cooling mediums for varying treatment time. The solution annealing treatment is carried out at temperature about 955°C for one hours and twenty minutes followed by an oil quenching. Further, the stabilized part is next subjected to a precipitation treatment at temperature 718°C for eight hours followed by the air cooling. The output of this process step 118 is a heat treated part.
[0051] In an embodiment, after the heating and treatment process is completed and the ring is cooled, at step 120, final machining of the ring is performed. The obtained final machined ring-shaped component 130 is ready to be put in service.
[0052] The person skilled in an art can easily appreciate the proposed method 200 which eliminates the pancaking operation, the punching, and the piercing operation by adding a doughnut operation on the hammer with the close die forging.
[0053] In an aspect, the process parameters like temperature, strain and strain rate are optimised with help of finite element modelling (FEM) where material flow, stresses, strain, and temperature are analysed. The modelling that uses mathematical models where simulations, which are conducted through specialised software using special algorithms, helps to understand the general behaviour of a fill up pattern, adiabatic heat rise, and load requirements. The simulation is worthwhile in terms of time and cost especially when the ring rolling operation is expensive for manufacturing of aerospace component.
[0054] In an embodiment, the doughnut die is designed in such a way that uniform deformation of the material takes place and hence, produces a defect free uniform microstructure. Due to the smooth material flow, lesser number of blows are required to fill up the doughnut. Defect free component with required final properties for the ring rolling produced in disclosed process with single heat on ring rolling machine and required dimensions are achieved that are again followed by testing and validation before putting in use. Due to innovative doughnut shape the load requirement in subsequent ring rolling operation is decreased as compared with conventional process and this has been proved through an example which is presented in the Para given below.
[0055] In an example, it has been proven and found that when a billet diameter 152.4 mm and height 62.5 mm is being used for conventional method. The weight of input billet is 9.3 kg. After the pancaking, the punching and the piercing operation, the weight is reduced around 7.5 Kg and cross section of the pancake is rectangle like shape. The ring rolling operation was carried on the radial ring rolling machine. During the ring rolling operation, desired dimensions could not be achieved in even with two heats so that the load requirement is increased and also requires multiple heating.
[0056] During process, the billet diameter is taken as 152.4 mm and height 52 mm. the weight of input billet is 7.7 kg. After doughnut machining the weight is around 6.4 kg, further in ring rolling operation due to innovative doughnut shape the final dimensions are achieved in one heat only and load requirement is reduced by 35% as compared to the conventional process.
[0057] Due to incorporation of doughnut operation and elimination pancaking, punching and piercing operation, better material distribution in the doughnut is achieved. Thus, ensuring minimal wastage of the material. It is thus clear from the example that with the proposed design of the doughnut, the same ring fills up with 15 to 20% lesser-input material.
[0058] Referring to FIG. 3, the sectional view of a pierced blank 126 is disclosed. The heated billet 122 when put under hot forging, a rectangular-like shape is shape achieved (shown in the FIG. 3). Therefore, based on this problem, the designing of the doughnut dies with help of the finite element modelling (FEM) is done in the disclosed method 200 as shown at step 210.
[0059] Referring to FIG. 4, the doughnut design obtained using the finite element method with multiple iterations is disclosed The strain and strain rate are optimized specifically for locations where significant deformations occur, with a focus on analyzing the material flow dynamics at these critical points. A portion showing better material distribution in the doughnut ensures that very little material is wasted. Thus, the proposed novel design of the doughnut fills up with a lesser input material. Yield improvement of 15% to 20% can be achieved using the invented design. Thus, reducing the material wastage.
[0060] Furthermore, FIG. 4 shows an angle (A) 402 refers as a draft angle and the draft angle 402 should lies between 5º to 10º. An angle (B) 404 should be in between 45º to 50º. When the angle (B) it was kept below than 45º, it has been observed that a load requirement is increased as well as under fill is observed at corners of the part. On the other hand, when the angle (B) 404 was kept greater than 50º, then forging defects were observed such as folds, laps during the ring rolling operations. Sharp corners are providing with a curve of a radius (R) 406 to smoothen the sharp corners.
[0061] In an embodiment, a rectangular shape cross section of pierced blank 126 obtained is shown in FIG. 3. The heated blank 126 is used as input for the ring rolling operation, the force or load requirement for rolling or expanding the diameter of blank 126 was very high. Further, to avoid cracking and flow localization, stain and strain rate distribution in doughnut die design was optimized and doughnut design is obtained as shown in FIG. 4. The load requirement is reduced significantly about 25% to 40% in subsequent ring rolling operation and final dimensions are achieved.
[0062] Referring to FIG. 5, the comparison between the pierced blank 126 produced during conventional Waspaloy forging process and the doughnut design 210 produced during Waspaloy forging process is shown.
[0063] Referring to FIG. 6A and 6B, the pattern of microstructure of the billet and the finished ring shaped components is disclosed. The corresponding microstructure analysis was carried out for raw material as well as finished part. The metal structure is defined under the international standards and denoted by American Society for Testing and Materials (ASTM) numbers and standards. The ASTM standards are formal, technical requirement that establish quality specifications. A cross-section of the billet 122 and the final ring shaped components 130 produced have been shown in FIG. 6A and FIG. 6B respectively. The initial grain size of billet 122 was observed 602 as ASTM number 4.5 as shown in FIG. 6A, whereas finish parts grain size is observed 604 as ASTM number 4.5 to 6.5 as shown in FIG. 6B. Partial dynamic recrystallization and dynamic recrystallization observed at surface and core respectively.
[0064] Referring to FIG.7, a block diagram of a method 700 of forging a Waspaloy alloy is disclosed. At block 702, the method 700 can include cutting a raw Waspaloy alloy material for a predefined billet 122. At block 704, the method 700 can include first heating the predefined billet 122 to a predefined first temperature using an electric furnace or sulphur free gas/oil fired furnace 802. At block 706, the method 700 can include forging the heated predefined billet 122 can be forged using a forging machine 804 to complete the deformation of the heated Waspaloy alloy predefined billet 122 in one heat cycle forging a doughnut 208.
[0065] In addition, at block 708, the method 700 can include first machining the doughnut 208 can be machined to remove flash and slug from inner diameter and outer diameter of the doughnut 208 producing a machined doughnut 210. At block 710, the method 700 can include second heating the machined doughnut 210 can be heated using the electric furnace or sulphur free gas/oil fired furnace 802 to the predefined first temperature.
[0066] In addition, at block 712, the method 700 can include of radial ring rolling the heated doughnut billet 210 may be rolled using a rolling machine 806 to produce a ring 128. At block 714, the method 700 can include treating the ring 128 can be heat treated. At block 716, the method 700 can include second machining the treated ring 128 can be machined for desired shape and dimension to produce a final ring 130.
[0067] In an embodiment, the predefined first temperature can be between a temperature range of 1020 degrees Celsius to 1120 degrees Celsius.
[0068] Referring to FIG.8, a system of forging a Waspaloy alloy is disclosed. The system 800 can include an electric furnace or sulphur free gas/oil fired furnace 802. The electric furnace or sulphur free gas/oil fired furnace 802 can be configured to heat a billet. In addition, the system can include a forging machine 804. The forging machine 804 can be configured to forge the billet into a doughnut in a single heat cycle. Further, the system can include a rolling machine 806. The rolling machine 806 can be configured to perform radial ring rolling on the doughnut to produce a ring 128. The rolled ring 128 can be heat treated for the achieving desired strength and hardness to produce a ring 128. The ring 128 can be machined to achieve desired shape and dimension. The final ring 130 can be ready to put in service.
[0069] In an exemplary embodiment, the typical mechanical properties achieved in the finish ring shaped components and test results meet the required specifications as shown in Table- 1.
Table- 1
Room Temperature Tensile Stress Rupture (Smooth)
(Condition – 649 °C & 689 MPA)
Specimen ID? 0.2%YS UTS % El. %RA Time to rupture % El. Failure Location
Min. AMS 5707 Spec. ? 110 ksi 160 ksi 15% 18% 23 hours 8% -
Sample - 1 127 181 23 21 114 hours 11.82% WGL
Sample - 2 121 179 17 19 Test Stopped 62 hours - -

[0070] The major problem solved by this disclosure is the introducing innovative doughnut shape for efficient use of material, higher production rate, reduction in reheating process, hence contributes in reducing manufacturing cycle time and cost. Also, due to innovative shape doughnut design, it is possible to expand the diameter and roll the ring to a designed target size with 25% to 40% reduced load as compare to the conventional process.
[0071] Thus, the present disclosure provides an improved, simple, and cost-effective method of Waspaloy forging, which is extremely important and economical process, especially for producing Waspaloy rings on low capacity Radial ring rolling machine. The disclosure leads to energy saving directly/indirectly contribute in reduction in carbon footprint.
[0072] While the above description contains much specificity, these should not be construed as limitation in the scope of the invention, but rather as an exemplification of the preferred embodiments thereof. It must be realized that modifications and variations are possible based on the disclosure given above without departing from the spirit and scope of the invention. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.
[0073] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE PRESENT INVENTION
[0074] The present invention overcomes the problems associated with the existing hot forging methods and provides a method and a system to produce a ring shaped Waspaloy alloy.
[0075] The present invention facilitates a hot forging method to produce a ring shaped Waspaloy component.
The present invention facilitates hot forging operation in a single heat cycle.
,CLAIMS:1. A method of forging a Waspaloy alloy, the method (700) comprising:
cutting (702), a raw Waspaloy alloy material for a predefined billet (122);
first heating (704), the predefined billet (122) to a predefined first temperature using an electric furnace or sulphur free gas/oil fired furnace (802);
forging (706), the heated predefined billet (122) using a forging machine (804) to complete the deformation of the heated predefined billet (122) in one heat cycle forging a doughnut (208);
first machining (708), the doughnut (208) to remove flash and slug from an inner diameter and an outer diameter of the doughnut (208) producing a machined doughnut (210);
second heating (710), the machined doughnut (210) using the electric furnace or sulphur free gas/oil fired furnace (802) to the predefined first temperature;
radial ring rolling (712), the heated machined doughnut (210) using a rolling machine (806) to produce a ring (128);
treating (714), the ring (128) using a heat treatment; and
second machining (716), the treated ring (128) for desired shape and dimension thereby producing a final ring (130).

2. The method (700) as claimed in claim 1, wherein the predefined billet (122) is a crack-free cylindrical billet.

3. The method (700) as claimed in claim 1, the predefined first temperature is between a temperature range of 1020 degrees Celsius to 1120 degrees Celsius.

4. The method (700) as claimed in claim 1, wherein the forging (706) is a close die forging.
5. The method (700) of claim 1, wherein the doughnut (210) defines a first predefined angle (402), a second predefined angle (404), and a radius (406), wherein the first predefined angle (402) is between a range of 5 degrees to 10 degrees, the second predefined angle (404) is between a range of 45 degrees to 50 degrees, the radius (406) facilitating the corners of the doughnut (210) to be smooth.

6. The method (700) as claimed in claim 5, wherein the first predefined angle (402), the second predefined angle (404), and the radius (406) enabling the radial ring rolling (116) to be performed with a predetermined load.

7. The method (700) of claim 1, wherein the forging (202) adopts a finite element modelling (FEM) to produce the doughnut (208).

8. The method (700) as claimed in claim 1, wherein the step of treating (714) is a heat treatment, wherein the method of heat treatment comprises the steps of:
third heating, the ring (128) at a solution annealing temperature of 955 degrees Celsius for one hours and twenty minutes;
quenching, the heated ring (128) using oil;
fourth heating, the quenched ring (128) at a precipitation treatment temperature of 718 degrees Celsius for eight hours;
air cooling, the heated ring (128) to a room temperature;

9. The method (700) as claimed in claim 1, the rolling machine (706) is configured to roll the heated machined doughnut (210) at a feed rate ranging between 3 millimetres per second to 5 millimetres per second to produce rings (128), wherein the rolling machine (806) is selected from a group comprising a planetary rolling mill, a tandem rolling mill, a cluster mill, a sendzimir mill, and a low capacity rolling machine.

10. A system of forging a Waspaloy alloy, the system (800) comprising:
an electric furnace or sulphur free gas/oil fired furnace (802) configured to heat a billet;
a forging machine (804) configured to forge the billet into a doughnut in a single heat cycle; and
a rolling machine (806) configured to perform radial ring rolling on the heated machined doughnut to produce a ring, wherein the ring is adapted to be machined for achieving desired shape and dimension, wherein the machined ring is adapted to be heat treated for the achieving desired strength and hardness to produce a final ring (130) ready to put in service.