August 2021 Volume 3

FORGING RESEARCH

PreformDesign for Flash-less Die Forging – North Carolina State University The overall objective of this study is to develop preform design schemes for flash-less die forging featuring 2D (axisymmetric and plane strain) and 3D problems. The schemes will be developed for use in conjunction with point tracking function in DEFORM 2D and 3D software packages. The mapping schemes are expected to contain algorithms for data transformation between DEFORM simulations and a CAD program. Market Research to Identify aWindow of Opportunity for FIERF on the Current Needs for RailroadWheels - University of Houston To investigate the current state of need for forged wheels used by heavy haul Class I railroads in North America and to identify potential window(s) of opportunity for the Forging Industry through Technology Development and Education: • To introduce and educate engineering technology students, mainly minorities, in the forging industry and manufacturing of wheels for heavy haul applications. • Survey the annual reports by the Federal Railroad Administration, Department of Transportation and the Association of American Railways concerning heavy haul wheels to identify needs, demand, supply, etc. • To investigate in the literature (journal articles, patents and books) on the current state of needs for heavy haul wheels and key aspects for improvement. Study ofThe Formation and Dissolution of Delta-Ferrite During High Temperature Forging Processing of Austenitic, Martensitic and PH Stainless Steels - University of Pittsburgh The major objective of this project is to develop a logical approach to study the formation and dissolution of Delta-Ferrite during high-temperature forging processing of austenitic, martensitic and PH stainless steels. This project proposes to explore alternative approaches to examine the dissolution kinetics behavior of Delta- Ferrite compared to conventional methods based exclusively on time and temperature treatments. The new approach intends to examine the impact of the synergistic effect of chemical composition, reheating temperature, deformation temperature, amount of deformation ( ɛ ) and strain rate ( έ ) on the dissolution behavior of Delta-Ferrite. The overall strategy is to fully characterize all aspects of the microstructure and Delta-Ferrite formation and dissolution using modern electron optics analytical techniques. The first goal is to carefully characterize all aspects of the microstructures in the as-received condition. The second goal is to conduct laboratory physical simulations of a representative forging process, and the final goal is to compare the effect of forging strategies on the formation and dissolution behavior of Delta-Ferrite for the different types of stainless steels to be studied in this program. This final step will be conducted under laboratory forging simulations.

Cost-Effective Lightweight Complex-Shaped Structural Components Made of MagnesiumAlloy Through a Hybrid Forging Process – University of Waterloo The ultimate objective of the proposed project is to advance a new hybrid forging process that leverages a preform optimization algorithm to produce cost-efficient, high performance, load-bearing magnesium components with complex geometries for automotive applications. Further project goals include: promote magnesium alloy forging as a viable method for manufacturing structural members for application in transportation industry; establish the link between structure-process-properties in forging of cast AZ80 Mg alloys through high fidelity mathematical/computational modelling and experimental validation, and optimize the forging of an exemplar automotive component, front lower control arm (FLCA), from a cast preform by minimizing material use and required forging force, and maximizing durability performance. Some of the deliverables include develop and verify mathematical forging models using commercial Finite Element (FE) package DEFORM-3D; develop an Artificial Intelligence (AI)-based multi- objective hybrid preform shape optimization technique for forging of AZ80 Mg alloy; design and produce optimum AZ80 preform for I-beam forgings; design and produce optimum AZ80 preforms for control arm forgings and establish thermomechanical data library for forging process of AZ80 Mg alloy. ■

FIA MAGAZINE | AUGUST 2021 80