August 2022 Volume 4

FORGING RESEARCH

To date, study of thermomechanical processing of engineering alloys has primarily focused on the influence of i) temperature and temperature gradients, ii) the distortional portions of stress, and iii) strain path on a final microstructure. Often neglected is the fact that during many of these manufacturing processes, large pressures are generated (> 1 GPa). These high pressures exerted during many standard thermomechanical processes provide more free energy to accelerate microstructure evolution (e.g., texture development and recrystallization rates), but also slow diffusional processes. Understanding the competition of these effects, which are generally not accounted for in process design, can help to improve the accuracy of microstructure prediction modeling efforts. Benchmarking Ergonomic Issues in the Forging Industry – Cleveland State University The overall object is to benchmark injury risk within the forging industry, focusing on upper extremity injuries. First, Cleveland State University (CSU) will review the safety statistics that are provided by the forging Industry Association and FIA member companies. Once the metrics have been reviewed, CSUwill conduct on-site assessments of individuals who have sustained an injury of the upper extremity, collecting biomechanical data (kinematics and kinetics) pertaining to a task that has been associated with repetitive movement disorders. Then CSU will create a biomechanical model of the upper extremity to ascertainmuscle and joint loads during the task being analyzed. This model will be matched to the gender and size of the most commonly injured worker. The overall goal of this exercise is to determine baseline conditions for a common injury, with the long-term objective of either modifying the task or the tool(s) used. Digital Twin for Metal Forging Using Open-source Software: Application to Bulk Temperature Control – Colorado School of Mines The goal of this project is to determine the feasibility of using open source software to create a digital twin of metal forging that would optimize targeted physical quantities of interest. As a case study, Colorado School of Mines will aim to develop an elemental digital twin system to control temperature and its spatial distribution in components during room and elevated temperature forging. If successful, the proof-of-concept will represent a stepping-stone for the development of more advanced digital twins capable of real-time optimization of forging/forming operations to prevent undesired, localized microstructural changes. Fabrication of Forging Preforms by Additive ManufacturingMethods –Cleveland State University The proposed project is an extension of micro-stage grant funded by FIERF last year. This project will investigate the feasibility of additive manufacturing processes (such as binder jet, selective laser melting, etc.) to minimize cycle time in the forging operations. We will study the effect of processing parameters on microstructure and mechanical behavior of 316 stainless steel fabricated via binder

jet/ selective laser melting followed by forging. A comprehensive literature survey will be conducted to review the state-of-the art in the subject matter and to introduce the students to stainless steel alloys, binder jet process, selective laser melting, forging, and sintering process. The 316 stainless steel exhibits excellent corrosion resistance as compared to other steels, primarily due to a passive layer of chromium oxide, which prevents the material from further oxidation. Stainless steel is widely used in industries such as aerospace, automotive, biomedical, etc. Additive manufacturing (AM) is a powerful manufacturing method that synthesizes three dimensional (3D) objects in layers directly from a digital definition. Post-processing plays an important role in most of metal additive manufacturing processes to achieve full densification. In the proposed study, post processing sintering will be done using forging, vacuum hot press, and spark plasma sintering for comparison. The investigation will include extensive metallographic work, with sample preparation, microscopy, and mechanical testing of parts with known processing history provided by the industry partner. Wire-arc Additive Manufacturing for Forging Dies – Georgia Southern University The objective of the stage grant proposal is to study the effect of wire-arc additive manufacturing on selected forging die material invented and fabricated by our industry partner. Wire-arc additive manufacturing is an emerging direct energy deposition technology, where the wire feedstock ismelted bywelding arc energy. The computer aided design (CAD) model is sliced into multiple layers and the computer numerical control (CNC) programming code is converted into native Robotic language. The process can deposit up to 15 lb/hr ideal for printing forging dies set rapidly. In this proposed project, WAAM process will be used to deposit block samples of a typical die steels such as 4340, Finkl FX, Ellwood Exell die etc. and F6301 or similar alloy for wear resistance. Using the wire fabricated from theWire-arc additive manufacturing process will create new business opportunities besides joining, repair and overlay. Improvements of H13 Forging Tool LifeThrough TiC Reinforced Inconel 6 – Lehigh University Themain objective of the proposedwork is to continuework initiated in a previous project conducted at Lehigh to select the best coating material for hot forging tooling made from AISI H13 tool steel to increase tool life. The selection of the material was based of literature review and was followed up by mechanical and tribological studies of selective laser melted (SLM) coupons from coating candidates such as: 316L stainless steel, Cobalt 188, Inconel 625 and H-13 tool steel as a reference material. Themaingoal of thecurrentproposal is tomodifythebestperforming material in the previous study, namely Inconel 625, by adding the reinforcement in the form of TiC particles. The expectation is that the new material will have superior mechanical and tribological properties mainly above 600 C where Inconel 625 shows significant softening effect. The coupons will be manufactured by selective

FIA MAGAZINE | AUGUST 2022 69