Development of large-sized Titanium alloy Ti6Al4V and nickel-based superalloy Inconel-718 forgings for Reusable Launch Vehicle-Technology Demonstrator flight

Ti6Al4V owing to its high specific strength and Inconel-718 due to its high strength and oxidation resistance at elevated temperatures, have been used in Reusable Launch Vehicle-Technology Demonstrator (RLV-TD). Achieving required properties in large cross-section aerospace quality forgings of these alloys is challenging and has not been reported earlier. Hence, thermo-mechanical processing cycles have been devised to realize forgings of similar to 1400 mm length in these alloys and successfully used in RLV-TD. Forgings of these alloys having desired microstructures and ultrasonic quality of Class-A1 as per AMS 2630 B standard have been realized. This article discusses the processing challenges and solutions thereof.