August 2021 Volume 3

FORGING RESEARCH

Metamorphic Manufacturing, aka "Robotic Blacksmithing": Experiments andModeling to Create Understanding of Incremental Deformation for Component Geometries with Known Microstructures - Colorado School of Mines The goal of the project is to show that Metamorphic Manufacturing (MM) is a potential pathway for the production of low-volume, performance-critical components. To do this, we will show that incremental deformation pathways enable unprecedented geometry and microstructure control, which are inaccessible to traditional deformation methods. The use of incremental forging results in previously unexamined deformation pathways, which means we have less understanding of microstructure and property evolution as a function of processing. These smaller, localized deformation increments, however, result in great opportunity to create desired microstructures at various locations within a component. If we can better understand microstructure evolution during complex imposed deformation sequences, we will not only make custom component geometries, but will also design those components to have improved performance. Here, we will examine, both experimentally and through modeling, a few important and representative deformation increments and engage students in the experimental performance, computational modeling, and technical understanding of these processes. High Temperature Properties of Wire-Arc Additively Manufactured 410 Stainless Steel - Georgia Southern University The objective of the micro grant proposal is to investigate the high temperature properties of wire-arc additively manufactured 410 martensitic stainless steel. Wire-arc additive manufacturing (WAAM) is a rapid, low cost direct energy deposition technology. The reported speed of WAAM is in the range of 5 lb/hr to 30 lb/ hr. It would be beneficial for the forging industry to fabricate the appropriate tooling rapidly using such technology. 410 stainless steel provides the necessary hardness for tooling applications, it has low cost, good machinability and printability however it hasn't been used for the forging/tooling application yet, although the steel has potential. Our previous studies (https://doi.org/10.1016/j. addma.2020.101821) have shown that 410 martensitic stainless steel have excellent roomtemperaturemechanical propertieswhen correct parameters are selected for the wire-arc additive manufacturing process, however there is not any data available at high temperature. During the time-period, the specimens for high temperature testing will be sectioned from the wire-arc additive manufacturing part to test the high temperature mechanical properties, mainly high temperature compression. The correct specification for this testing will be discussedwith our industry partner once the project kicks off. The micro grant will enable the mechanical engineering students’ involvement in the training, participation and education related to forging thus preparing them for careers in the forging industry.

High Strength, High Toughness Martensitic Stainless Steels - Illinois Institute of Technology/ TPTC The overall objective of this FIERF project is to investigate and identify process variables that affect the resulting strength and toughness of forged martensitic stainless steels. There is significant demand for the production of physically large forgings of high strength stainless steel alloys, such as 17-4PH, 15-5PH to be used as fracking blocks. The demanding design requirements for these structures, specify high strength and fracture toughness levels that can only be attained through proper forging and heat treatment to induce the formation of a precipitation hardened, martensitic structure. Typical production routes for processing forged blocks with cross-section dimensions on the order of 22” x 26” start with a clean ingot that has been subject to ladle metallurgy and vacuum degassing. The ingot is then open-die forged into a square bar and allowed to air cool prior to heat treatment. To achieve themartensitic microstructure, the forged blocks are austenitized, water quenched and tempered/aged. Due to the physically large size of the forged bar, the non-uniform heat transfer that occurs during heating and cooling of the forgings may lead to heterogeneous microstructural features that result from variations in parent austenite grain size, carbide distribution, fraction of retained austenite, etc. In this effort, Illinois Institute of Technology (IIT) will partner and work closely with Finkl Steel in understanding the interrelationships between thermal-mechanical processing parameters and the resulting microstructure/properties of the forged martensitic stainless steel blocks. Input and active participation are also expected from FIERF and other FIA partner organizations. Robotic Forging Cell Development for Education and Research - Phase 2 - Marquette University The forging industry has begun to pursue efforts to implement robotic automation based on the increasingly difficult task of finding people who are willing to work in forge shops. The significance of this problem is evidenced by the fact that the Forging Technology Roadmap has identified increased development of forging related robotics as a key priority item. This project seeks to enhance the capabilities of a robotic forging cell used to simulate forging in an educational environment. Currently a robotic cell is being developed for research and learning using plasticine to develop initial capabilities and enable reasonable operation/maintenance costs. The cell, which essentially replicates a forging operation (press, tooling, tender/operator) currently relies on manual lube application when lubrication is to be used in a study. As such this does not permit the desired level of consistency/control. Thus, it is proposed to have 4 engineering students enrolled in the capstone design group at Marquette University to develop and implement a robotic based lube sub-system and incorporate it in the existing cell.

FIA MAGAZINE | AUGUST 2021 79