Controlled microstructure for superalloy components

A method comprising:

• heating a substrate to within a forging temperature range, wherein the substrate comprises a nickel-based superalloy, and wherein the forging temperature range is below a grain boundary phase solvus temperature of the substrate;
• applying a plurality of die forging stages to the substrate to form a component preform;
• maintaining the substrate within the forging temperature range during and between application of each of the plurality of die forging stages;
• and
• cooling the component preform after completing the plurality of die forging stages, wherein a portion of the component preform includes a relatively low delta phase region, and wherein a volume fraction of a delta phase in the relatively low delta phase region is less than 80% of an average volume fraction of the delta phase in the component preform;
• and
• processing the component preform to form a component, wherein the component includes a relatively high stress portion relative to other portions of the component, and wherein the relatively high stress portion of the component is at least partially positioned within the relatively low delta phase region.