August 2026 Volume 8

FORGING RESEARCH

summarized. The 6xxx alloy will be characterized both before and after hot deformation processes conducted with a Gleeble thermal mechanical simulator. This will explore a deformation space made up of changes in strain, strain rate, and temperature. Electron Backscatter Diffraction (EBSD), a characterization technique associated with a scanning electron microscope (SEM), will be the main microstructural characterization method for the samples. EBSD can reveal quantitative grain information such as grain size, aspect ratio, and the crystal orientation of each grain. Although optical microscopy (OM) can also reveal grain size and shape after etching, EBSD adds crystal orientation information, and can also export all of its data in a friendly format to enable subsequent finite element modeling. This makes EBSD ideal for this project, where the grain size, shape, and orientation with respect to the wheel surface is critical in determining the final corrosion and fatigue resistant properties. From the modeling perspective, this project aims to enhance and validate microstructure evolution models during thermo-mechanical processing of Al6xxx alloys. Validated grain size and precipitation evolution models along with strength prediction model results will be compared with the measured results from a selected Accuride component. Industry Impact The direct industrial benefit for the project will be to provide a robust model for 6xxx aluminum alloys that can be used to design and engineer new forgings through accurate prediction of the final grain structure and properties. “It’s going to help the industry, taking more of the guessing out of deformation and grain flow.” Ritz commented. Currently, hot deformation experiments using the Gleeble are underway, and characterization of the samples using EBSD and other techniques have begun. As different experimental datasets are completed, the data will be passed to SFTC to validate and refine their model as the project matures. On a broader scope, this developed model could be applied not only to future wheel designs at Accuride, but other forged components (such as in the aerospace industry) manufactured out of the same alloy. “Success is that the model works; and becomes something the whole industry can use.” Ritz stated. In addition, the project will provide a methodology of data collection and analysis that has the potential to develop similar microstructural finite element models for additional alloy systems. Funding was secured for the collaborative initiative through the National Center for Manufacturing Sciences (NCMS) Commercial Technologies for Maintenance Activities (CTMA) Program and the Office of the Deputy Assistant Secretary of Defense, Materiel Readiness (ODASD-MR).

Colton Ritz Metallurgical Engineer Accuride Corporation Email: critz@accuridecorp.com

Dekland D. H. Barnum, PMP Senior Project Manager, FORGE-IT Lead Advanced Technology International Email: dekland.barnum@ati.org

Matt Gallaugher, Ph.D. Technical Director Forging Industry Association Phone: 216-781-6260 Email: matt@forging.org

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