August 2024 Volume 6

MATERIALS

MORE ON THE FIA FORGING FAILURE ANALYSIS COURSE By FIA Staff

I n the Fall of 2022, FIA offered an approximately one-hour training session on the basics of failure analyses which includes a great overview of the tools used in getting to the root cause of failures (see “Failure Analysis of Metal Problems” on the FIA website under Forging University). This has proven to be a very popular course. In the Summer of 2023, FIA added a course focused on failures that can occur before the forging is shipped to end user. This new course was designed to take a step back in the life cycle of a forging. The new course explained the issues that can occur in forging process and used specific examples of issues from the main forging processes: open-die forging, closed die forging, and seamless rolled-ring forging (see “Failure Analysis of Forging Problems” on the FIA website under Forging University). This article is a promotion of FIA Forging University and expands on the original announcement and introduction of new FIA forging online training courses which was published in the FIA Magazine November 2023 issue. This article includes related content on Failure Analyses that is planned to be added to existing courses on this subject.

There are many reasons this is vital such as: • Safety concerns and prevention of injury or, worse, lives lost. • Legal liability issues determine responsible parties. • Economic liability costs, legal costs, and lost revenue. • Other reasons such as to validate or calibrate design assump tions and implement lessons learned. The course format takes the viewer through an introduction to forg ings. This includes an explanation of the basic forging process, the main forging processes, and why the forging process is used. The course transitions towards the failure analysis process and exam ples with a description of potential issues and whether they are pre existing (i.e. ingot porosity) or occur during the forging process (i.e. cracking/tearing). The list of defects covered includes laps/seams,

The goal of this new course was to create a program explaining the issues that can occur with specific examples of issues stemming from the main forging processes: open-die forging, closed die forging, and seamless rolled-ring forging. Why is the early detection of forging issues and subsequent failure analysis important? To prevent defective material from getting to the customer.

FIA MAGAZINE | AUGUST 2024 33