Forge-Diffusion Bond Titanium Rotor Hub Evaluation.

Fabrication of complex titanium components by means of the forge-diffusion bond process has been successfully demonstrated and evaluated by mechanical properties testing. The process is technically feasible but, in its present approach, would not be cost effective for large components. The purpose of this program was to establish the manufacturing methods and technology necessary to fabricate large Ti-6Al-4V components at low overall cost by means of the forge-diffusion bond process. The technical approach to achieve this concept consisted of three phases the determination of an optimum process condition by evaluation of small test specimens cut from simple pancake forgings which had been fabricated with different processing conditions the utilization of the optimum process condition in the fabrication and evaluation of a risk reduction component which was a single arm of the H-53 Helicopter Elastomeric Main Rotor Hub and finally, the manufacture of the full-size main rotor hub. The first two phases of this concept have been successfully completed in this program.