Method of shear forge bonding and products produced thereby

A method for shear forge bonding first and second metal parts having forging compatible compositions, comprising the steps of:

• a. sizing first and second metal parts for joining across a shear forged bond line;
• b. disposing said metal parts in forging dies configured to prevent said parts in a bonding-effective orientation;
• c. shearing first and second surfaces, one on each of said metal parts, located proximately and opposite one another across a gap, under controlled conditions of temperature and atmosphere selected to prevent the formation of any bonding disruptive surface contamination on the sheared surfaces;
• d. forging said parts to close said gap and bring said sheared surfaces into contact, under controlled conditions of temperature, pressure, atmosphere and peripheral constraint, to yield an autogenous bond therebetween;
• wherein said disposing step comprising disposing said first metal part in contact with a first forging die and said second metal part in contact with a second forging die, each of said dies having an area of generally complementary configuration respecting the part received therein;
• and further wherein each of said metal parts is fitted with a cutter ring for shearing a surface on the part disposed in contact with the other die.

A method for shear forge bonding first and second metal parts having forging compatible compositions, comprising the steps of:

• a. sizing first and second metal parts for joining across a shear forged bond line;
• b. disposing said metal parts in a bonding-effective orientation;
• c. shearing first and second surfaces, one on each of said metal parts, located proximately and opposite one another across a gap, under controlled conditions of temperature and atmosphere selected to prevent the formation of any bonding disruptive surface contamination on the sheared surfaces;
• d. forging said parts to close said gap and bring said sheared surfaces into contact, under controlled conditions of temperature, pressure, atmosphere and peripheral constraint, to yield an autogenous bond therebetween;
• wherein said first and second metal parts comprise nickel-based superalloys.