February 2020 Volume 2

Official Publication of the Forging Industry Association Fluid EndBlockCoalition’s First Hearing at ITC page 29 Methods and Practices for ControllingDie Temperature page 38

February 2020 forging.org

Cover Story page 3

FIA MAGAZINE | FEBRUARY 2020 1 Laboratory Testing to Identify Permanent PVDCoatings to Minimize Lubricant UseDuring Forging: Final Report page 51 Is There Really anOff-The-Clock? page 42

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FIA MAGAZINE | FEBRUARY 2020

PRESIDENT'S NOTE

A Brief Look Back

Well, it’s been two years since I walked into the offices of the Forging Industry Association. It’s been tough at times but I still can’t believe my good fortune. I’m fortunate to have been gifted with a great team and had some great luck finding a couple more gems during a tough hiring market. I’m also fortunate to be

Ike also found a path for nominally involving his children in the business, hired a professional president to guide them, and everything is looking up at ETNA Products. I could have written this paragraph on any number of forging companies I’ve met with, but I’ve known Ike now for 32 years and wanted to share his example of someone building something and creating value and opportunity for his people. It’s a great story that I’m so glad I got to experience - even from the sidelines. Issue #1 at the FIA–Fair Trade Fortunately, the fair trade issue was made crystal clear to me in my second week at FIA when meeting with a longtime member and it was corroborated by other industry leaders. There will be no FIA without members who are thriving and, at present, the industry continues to be hampered by unfair trade. Fast forward: the Fluid End Block (FEB) Coalition will have its first conference at the United States International Trade Commission (ITC). Many readers and those who attend FIA member events are well aware of trade attorney firmCassidy Levy Kent LLP led by trade attorneys Jack Levy, Myles Getlan, andThomas Beline.This trio has educated and led FIAmembership on all matters related to fair trade sinceMarch of 2018.The FEBCoalition is made up of Ellwood City Forge and Finkl Steel, with FIA as a non-funding supporter. You can read more on this on pg. 29 of this issue. FinalThoughts I look forward to seeing many of you at upcoming events. The Midwest Meeting on January 27 will have happened, and we’ll look for you on Lobby Day, February 25-26, in Washington D.C.. Next, we’ll have the FIA Annual Meeting in Naples, FL. As always, please reach out to me with any thoughts, concerns, or questions. We’re here to serve and would like to hear from you. We are always open to an invitation to visit your plant. I regularly get out and try to see as many members as possible. Don’t be shy - ask for a visit. Sincerely, James R. Warren

the "external guy" who gets to visit with members all over North America and take the pulse - first-hand - of what is happening. It has not been all roses with the energy market and fair-trade issues but the last two years have had some bright spots. Not so sure about the next year with its tough economy, EVs, and an election, but one thing I know is that this industry is resilient and won’t cower. A LeaderThen and Now

I had the great fortune of recently meeting up with one of my earliest mentors from my first professional job, 1988 at SME, while visiting with our newest FIA member Summit Steel in Chagrin Falls, OH Ike Tripp, Jr., president of ETNA Products, a

metal forming lubrication supplier. Ike’s just down the street from Summit Steel and had 20 minutes to spare for a visit. I remember Ike being tough and demanding excellence as we assembled industry programs. During our conversation I whined a bit about industry consolidation and how it’s taken a toll on FIA’s membership (and dues). Ike shared that there’s been no shortage of suitors for his company and it would have been easy to sell out. But that’s not Ike. He couldn’t let his loyal staff down as buyers would likely come from his competition and many employees would lose their jobs through consolidation. It made me think about all the forging owners and leaders I’ve met these two years and how much pride they conveyed regarding their staffs: the longevity of commitment to the company, work ethics, joy brought to the workplace, etc. Let’s hear it for all the owners who stick it out and take care of their people! I celebrate you!

President and CEO Forging Industry Association

PUBLISHER James R. Warren jwarren@forging.org CONTRIBUTOR Angela Gibian angela@forging.org Editorial Staff

Board of Directors

Gerald Bornman Joseph Cipriani Robert Dimitrieff Mike Gill Jeff Klingerman

Chelsea Lantto Douglas McIntyre David Mesick John Pale Greg Timmons

OPERATIONS Joseph R. Boni joe@forging.org DESIGN Lorean Crowder lorean@forging.org

CHAIRMAN Alex Jennings VICE CHAIRMAN Kurt Ruppenthal

FIA MAGAZINE | FEBRUARY 2020 1

CONTENTS

FEBRUARY 2020 | VOLUME 2

p. 3

p. 44

p. 47

PRESIDENT'S NOTE 1 A Brief Look Back INDUSTRY NEWS & CALENDAR 3 International Forging Congress 2020 25 Interpower Induction Celebrates 25 Years of Building Induction Systems 26 FIA Upcoming Events 28 Gasbarre Partners with Humberto Bastidas and Thermal Technic Furnace Solutions to expand our footprint in Mexico WASHINGTON UPDATE 29 FIA Lobby Firm Report 31 Fluid End Block Coalition First Hearing at International Trade Commission ECONOMIC UPDATE 36 FIA Quick Read Economic Update MATERIALS 40 Methods and Practices for Controlling Die Temperatures 42 How Rough is Smooth?

OPERATIONS & MANAGEMENT 44 Is There Really an Off-the Clock? 46 Are You Engaging Your Employees? 47 Apprenticeship Programs: 47 Vital to Closing the Skills Gap ASSOCIATION NEWS 49 Welcome New FIA Members 50 FIA Plant Engineering and Safety Committees Meet at Asahi Bluegrass Forge FORGING RESEARCH 51 Project Report: Direct from Forge Intensive Quenching (DFIQ TM � Process for Steel Forgings 53 Laboratory Testing to Identify Permanent PVD Coatings to Minimize Lubricant Use During Forging: Final Report MEMBERS SPEAK 62 This Decade Needs New Strategies to Keep Us Strong and Free

DEPARTMENTS 1 President's Note 3 Industry News & Calendar 29 Washington Update 36 Economic Update 40 Materials 44 Operations & Management

49 Association News 51 Forging Research 62 Members Speak

OfficialPublicationofthe Forging IndustryAssociation FluidEndBlockCoalition’sFirst Hearingat ITC page29 MethodsandPracticesfor ControllingDieTemperature page38

February2020 forging.org

CoverStory page3

IsThereReallyanOff-The-Clock? page42 LaboratoryTestingto Identify PermanentPVDCoatingsto MinimizeLubricantUseDuring Forging:FinalReport page51

For advertising contact info@forging.org

FIA Magazine (ISSN 2643-1254 (print) and ISSN 2643-1262 (online)) is published 4 times annually, May, August, November and February by the Forging Industry Association, 1111 Superior Ave., Suite 615, Cleveland, OH44114. Telephone: (216) 781-6260, Fax: (216) 781-0102. Print version distributed at no charge only to members of the Forging Industry Association. Digital version distributed at no charge to qualified individuals. Subscription requests available at www. forging.org. Printed in the U.S.A. Periodicals postage paid in Cleveland, OH and additional mailing offices. POSTMASTER: Send address changes to Forging Industry Association, 1111 Superior Ave., Suite 615, Cleveland, OH 44114. Copyright © 2020 by the Forging Industry Association in both printed and electronic formats. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the publisher. The publisher is not responsible for product claims and representations or for any statement made or opinion expressed herein. Data and information presented by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

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FIA MAGAZINE | FEBRUARY 2020

INDUSTRY NEWS & CALENDAR

International Forging Congress 2020

What is the International Forging Congress? International Forging Congress (IFC) is a global event that brings together key players from the international forging community to exchange information and experiences. IFC features forging industry technical and business-oriented presentations. In addition, exhibitors display their forging-related products and services to IFC attendees. The IFC was founded in 1953 and is organized by national forging associations from all over the world. The IFC travels the globe and is hosted in a different country every three years. This year the 23rd International Forging Congress will be held in the United States for only the fourth-time, last being hosted by FIA in 2008. The 23rd IFC will take place September 19-21, 2020 in Chicago, USA.

Here is where the IFC has been held since its inception in 1953: • 1953 1st IFC Gleneagles, Scotland/UK • 1956 2nd IFC Munich, Germany • 1959 3rd IFC Paris, France • 1962 4th IFC London, UK • 1965 5th IFC Munich, Germany • 1968 6th IFC Washington, USA • 1971 7th IFC Brussels, Belgium • 1974 8th IFC Nice, France • 1977 9th IFC Kyoto, Japan • 1980 10th IFC London, UK • 1983 11th IFC Cologne, Germany • 1986 12th IFC Orlando, USA • 1990 13th IFC NewDelhi, India • 1993 14th IFC Venice, Italy • 1996 15th IFC Paris, France • 1999 16th IFC Beijing, China • 2002 17th IFC Dusseldorf, Germany • 2005 18th IFC Nagoya, Japan • 2008 19th IFC Chicago, USA • 2011 20th IFC Hyderabad, India • 2014 21st IFC Berlin, Germany • 2017 22nd IFC Hangzhou, China

FIA MAGAZINE | FEBRUARY 2020 3

INDUSTRY NEWS & CALENDAR

Why You Should Attend IFC 2020 in Chicago, USA Technical and Business-Oriented Presentations Beginning Monday, September 20, 2020 through Tuesday, September 21, 2020, there will be over 40 technical and business oriented presentations by forging industry leaders and academics worldwide. Presentations on forging research and technology include the following topics:

Networking IFC is a global event that brings together key players from the international forging community to exchange information and experiences. Perhaps the biggest reason you should attend IFC 2020 is the social interaction it encourages between forging peers. IFC 2020 will include various opportunities to network and engage with other attending delegates. Throughout the event delegates will be encouraged to interact, ask questions and share knowledge about industry advancements, economics, technologies and best-practices. Group lunches, coffee breaks and time in the Exhibit Hall will help to foster new relationships and provide delegates time to meet with one-another throughout the Congress. One featured networking opportunity at the 2020 International Forging Congress is the Opening Reception, which will be held at the Museum of Science and Industry on September 19, 2020. Opening Reception attendees will enjoy premium cocktails, a variety of cuisines and access to museum exhibits, including interactive flight simulators, a Boeing 727 and more. (see page 5 for more information) Another Congress highlight that will bring the IFC attendees together for social networking and engagement is the Closing Banquet on September 21, 2020 at the Marriott Magnificent Mile Downtown. The banquet will be held in the Chicago Ballroom and feature a duo-plated dinner, beer and wine, and entertainment by Dakota Horvath and The City Lights Orchestra. (see page 12 for more information) Don’t miss this unique opportunity to meet and greet top-level forging and supplier executives from around the world.

• Forging Equipment • Plant Productivity • Heat Processing &Treatment • Materials • Tooling • Software Simulation • Material Handling • Automation • Industry 4.0 (IIoT) • Maintenance • Product Design • Light weighting • Alternative Technologies

Exhibition IFC 2020 will feature 43 booth and 17 table top displays by leading suppliers to the forging industry from around the world. IFC attendees will be able to see the latest forging technology available from forging suppliers. (See page 7 for the floor plan of the fifth floor of the ChicagoMarriott Magnificent Mile Downtown exhibit room where the booths will be displayed and the foyer area where the table tops will be located).

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FIA MAGAZINE | FEBRUARY 2020

INDUSTRY NEWS & CALENDAR

DAY 1 Saturday, September 19

While at this private event attendees will be able to experience MSI’s outstanding exhibits including:

Registration 7:30 a.m. – 4:00 p.m.

Marriott Magnificent Mile Downtown 540 N. Michigan Ave, Chicago, IL 60611 IFC delegates and accompanying persons will be provided with their credentials by FIA staff at the IFC registration desk. The IFC Registration Desk is located on the 5th Floor of the Marriott Magnificent Mile Downtown. Congress delegates will be checked-in for the event and provided with their name badge and the official IFC program guide. Delegates can collect these items on behalf of their accompanying persons, or accompanying persons are welcome to go to the IFC

registration desk on their own. Opening Reception 6:00 p.m. – 9:00 p.m. Museum of Science and Industry 5700 S. Lake Shore Drive Chicago, IL 60637 www.msichicago.org

Interactive Flight Simulator Attendees are encouraged to climb aboard and try their skills as either a pilot or gunner in a historic aircraft: choose from the P-51 Mustang, F-4 Phantom II, F-16 Fighting Falcon and more. Launch and take to the skies as you climb, dive, and roll 360º.

IFC 2020 will kick-off with an Opening Reception on September 19, 2020 at the Museum of Science and Industry. The private event will feature multiple dinner stations, highlighting a variety of cuisines including a specialty station with “Chicago-style” food options. The reception also includes unlimited premium cocktails and beverages. The Museum of Science and Industry (MSI) is located in Jackson Park, in the Hyde Park neighborhood. It is housed in the former Palace of Fine Arts from the 1893 World’s Columbian Exposition. It is currently the largest science center in the Western Hemisphere. Chicago’s extensive Museum of Science and Industry pays tribute to the city’s innovative roots, showcasing more than 35,000 artifacts and a variety of hands-on exhibits meant to inspire creativity.

The Great Train Story &Transportation Gallery A centerpiece of the Transportation Gallery, is an interactive model railroad which features more than 20 trains winding through a continental journey replicated in astonishing detail and scope.

FIA MAGAZINE | FEBRUARY 2020 5

INDUSTRY NEWS & CALENDAR

Coal Mine Since 1933, Coal Mine has taken MSI guests down the mineshaft, along the rails, and through the walls of a true-to-life coal mine. It was the Museum's very first exhibit, and it's been a guest favorite ever since. Participants will enjoy this descent into a "working" coal mine, an engaging tour of mining methods and machinery through the years.

727 Take Flight Attendees can explore the inner and outer workings of an actual United Airlines Boeing 727 as they climb aboard the plane's fuselage and learn about the technology that shapes commercial aviation. Transportation to and from the Opening Reception will be available. Motorcoaches will pick-up outside of the Marriott Magnificent Mile Downtown. The motorcoaches will begin boarding at 4:45 p.m. to take guests to theMuseumof Science and Industry.The motorcoaches will then depart from theMuseumof Science and Industry beginning at 9:15 p.m. and return to the Marriott Magnificent Mile Downtown.

ToyMaker 3000 This exhibit demonstrates the entire process of manufacturing a toy on a modern assembly line. Attendees will be able to follow along every step of the way, from parts to packaging. The speed and precision is quite a show.

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FIA MAGAZINE | FEBRUARY 2020

INDUSTRY NEWS & CALENDAR

Exhibition Sunday, September 20 Monday, September 21

IFC 2020 will feature 43 booth and 17 table top displays by leading suppliers to the forging industry from around the world. IFC attendees will be able to see the latest forging technology available from forging suppliers. All 43 booth displays are located in the exhibit room as shown in the floor plan below; all 17 table top displays are located in the foyer areas. To see the current list of IFC exhibitors, please go to the FIA website at www.forging.org

FIA MAGAZINE | FEBRUARY 2020 7

DAY 2 Sunday, September 20 INDUSTRY NEWS & CALENDAR

Metamorphic Manufacturing: Processing Pathways to Manufacture CustomGeometry Components with Tailored Microstructures Kester Clarke, Colorado School of Mines Presentation Room B Advanced Remote Troubleshooting andMaintenance Techniques for Induction Heaters Joe Stambaugh, Ajax TOCCO Presentation RoomC Keynote Presentation: Dr. Chris Kuehl, Armada Corporate Intelligence Presentation Room A Chinese Forging Trends Update Zhang Jin, Confederation of Chinese Metalforming Ind. Presentation Room A Indian Forging Trends Update Murali Shankar, Association of India Forging Ind. Presentation Room A ForgingMore IntelligentlyThrough Workpiece Tracking, Adaptive Control andMachine Learning Mathias Liewald, Prof. Dr. and Celalettin Karadogan, Dr. Institute for Metal Forming Tech. - Buffet Lunch – 4th Floor Exhibit Hall Open Coffee &Tea Break Exhibit Hall Open

Congress &Exhibition 7:30 a.m. - 4:55 p.m.

Marriott Magnificent Mile Downtown 540 N. Michigan Ave, Chicago, IL 60611 7:30 a.m. – 5:00 p.m. Registration - 5th Floor 7:30 a.m. – 8:30 a.m.

Continental Breakfast - 4th Floor Exhibit Hall Open Congress Welcome Jeff Jones, Chairman, International Forging Congress Presentation Room A North American Forging Trends Update James R. Warren, President &CEO, Forging Industry Association Presentation Room A European Forging Trends Update Tobias Hain, President, EUROFORGE Presentation Room A Engineered Residual Stress Fields in Tool and Die Applications by Laser Shock Peening Stan Bovid, LSP Technologies Presentation Room A Innovative High Performance Tool Steels for Hot-Forging Applications Michael Hirtler, voestalpine BÖHLER Edelstahl Presentation Room B Investigation of Directional Surface Topography In Forging.

8:30 a.m. – 8:40 a.m.

8:40 a.m – 9:00 a.m.

10:20 a.m. – 11:00 a.m.

11:00 a.m. – 11:30 a.m.

9:00 a.m – 9:20 a.m.

11:30 a.m. – 11:50 a.m.

9:25 a.m. – 9:50 a.m.

11:55 a.m. – 12:15 p.m.

12:15 p.m. – 2:00 p.m.

2:00 p.m. – 2:25 p.m.

Joseph P. Domblesky, Marquette University Presentation RoomC

University of Stuttgart Presentation Room A

9:55 a.m. – 10:20 a.m.

Lightweight Forging – A Success Story in Four Chapters Hans-Willi Raedt, Hirschvogel Automotive Group Presentation Room A

Finite Element Modeling inMetal Forming and Forging Industries - What to Know andWhere to Apply Ming (Henry) He,

The Timken Company Presentation Room B

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FIA MAGAZINE | FEBRUARY 2020

INDUSTRY NEWS & CALENDAR

3:25 p.m. – 4:00 p.m.

Coffee &Tea Break Exhibit Hall Open

Die Set Construction Options for Post Forging Operations Steven Janiszewski, Superior Die Set Presentation RoomC TheWorld’s Biggest Pull-Down Hydraulic Closed-Die-Forging Press in USA at Weber Metals Serdar Tuncel, SMS Group GmbH Presentation Room A The New Trend in Hot and WarmClosed-Die Forging: Intelligent Lubrication Franck Belloy, Quaker Houghton Presentation Room B Robotic Die &Component

4:00 p.m. – 4:25 p.m.

Review of Hot Forging Steel Wear Analysis andModelling of Cost Reduced Solutions Salvador Perez, CIE Galfor Presentation Room A HowVirtual ProcessManufacturing Will Meet Today’s and Tomorrow’s Challenges in the Fieldof Aluminum Forging Nicolas Poulain, Transvalor Americas Corp. Presentation Room B Isostatic Forging -The Fit with Other Forging Processes Robert M. Conaway, Isostatic Forging International Presentation RoomC ModernDesign Solutions of Forging Devices for Forging Ingots and Blanks Using Four Fies on Hydraulic Forging Presses Sergey Kuralekh, Lazorkin Engineering LLC Presentation Room A Newest Developments in Ring Rolling Robert Bolin, SMS Group Inc. Presentation Room B Friction Stir Additive Consolidation for Bulk Forging Feedstock Kester Clark, Colorado School of Mines Presentation RoomC

2:30 p.m. – 2:55 p.m.

Welding System Chris Kerchkof,

Eureka Welding Alloys Presentation RoomC

3:00 p.m. – 3:25 p.m.

4:30 p.m. – 4:55 p.m.

Comparison of Mechanical and Hydraulic Forging Presses Ken Setze, Schuler Incorporated Canton

Presentation Room A Bringing the IIoT to Forging Forefront Paul Hogendoorn, FreePoint Technologies Presentation Room B

Applying Non-Destructive ExaminationMethods to Forge Presses

Ronald P. Manganello, Carlesa NDE Services Presentation RoomC

FIA MAGAZINE | FEBRUARY 2020 9

DAY 3 Monday, September 21 INDUSTRY NEWS & CALENDAR

Congress &Exhibition 7:30 a.m. - 2:55 p.m. Marriott Magnificent Mile Downtown 540 N. Michigan Ave, Chicago, IL 60611 7:30 a.m. – 8:30 a.m.

Automating the Uniformity Certification Process for the Forge and Heat Treat Furnaces Justin Dzik, Fives North American Combustion, Inc. Presentation Room B State of Art in Forging Lightweight Alloys and High Temperature Super Alloys Mr. Carlo Maffei, FICEP SPA Presentation RoomC Initiative Lightweight forging; Geometries Made Easy by Forging Marco Laufer, Hammerwerk Fridingen GmbH Presentation Room A 3C's (Cool, Comfortable and Clean) Danny Pittman, Asahi Bluegrass Forge Presentation Room B Porosity and A-Segregation Prediction in Hollow Ingots for Large Forgings Ovidiu Bogdan, Industrial Soft Presentation RoomC Effect of Billet Forging Temperature on Grain Size, Heat Treat Response The MOBI-HEARTH Furnace® - TheWorld's Most Flexible Batch Heat Treating System Michael K. Klauck, Can-Eng Furnaces International Presentation Room B Optimization of BlankWeights in Forging Lines Michael Siegl, Linsinger Presentation RoomC and Final Part Properties Chuck Hartwig, ThermTech Presentation Room A Coffee &Tea Break Exhibit Hall Open

Continental Breakfast - 4th Floor Exhibit Hall Open Registration Desk – 5th Floor

8:00 a.m. – 2:00 p.m. 8:30 a.m. – 9:00 a.m.

Keynote Presentation: Dr. Don McNeely, Chicago Tube & Iron Co. Presentation Room A

10:20 a.m. – 11:00 a.m.

9:00 a.m. – 9:20 a.m.

Japanese Forging Trends Update Futoshi Suzuki, JFA (Presentation Room A) IForge and Industry 4.0 - Digitalization is Key for Performance Enhancement in the ForgingWorld Martin Scholles, SMS Group GmbH Presentation Room A Increasing Forging Die, Tool Life, Preventing Rejections and Reducing Energy Consumption by the use of Protective Coatings Srikar Shenoy, Steel Plant Specialties, LLP Presentation Room B I mprove Your Plant Productivity by Choosing the Right Lubricant and the Right Material Todd Smith, Condat Corp. Presentation RoomC Laboratory Testing to Identify Permanent PVDCoatings to Minimize Lubricant Use During Forging Kester Clarke, Colorado School of Mines Presentation Room A

11:00 a.m. – 11:25 a.m.

9:25 a.m. – 9:50 a.m.

11:30 a.m. – 11:55 a.m.

9:55 a.m. – 10:20 a.m.

11:55 a.m. – 2:00 p.m.

Buffet Lunch – 4th Floor Exhibit Hall Open

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INDUSTRY NEWS & CALENDAR

2:00 p.m. – 2:25 p.m.

Forge Shop of a NewGeneration JimKravec, Amir Tanbakouchi, Dr. Rene von Dombrowski, Siempelkamp Maschinen & Anlagenbau GmbH Presentation Room A Vibration Isolation and Forge Shop Foundations Victor Salcedo, GERB Vibration Control Presentation Room B CFDModelling of Immersion Quenching Process for Prediction of Metal partsThermodynamic Conditions DavidGreif, AVL-AST d.o.o. Slovenija Presentation RoomC Experience with Industry 4.0 at Equipment In Open/Closed Die Forging Shops and Visions in Automation Rainer Dango, Dango &Dienenthal Maschinebau Presentation Room A

Enhancing Tool Life by Manipulating the Punch &Die Elastic Strain Field During Forging Gracious Ngaile, North Carolina State University Presentation Room B

How Forging Simulation Saves Time andMoney Nick Biba, Qform/Forge Technology, Inc Presentation RoomC Closing Banquet Chicago Ballroom, Marriott Magnificent Mile

6:30 p.m. – 9:30 p.m.

2:30 p.m. – 2:55 p.m.

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INDUSTRY NEWS & CALENDAR

Closing Banquet 6:30 p.m. - 9:30 p.m.

Marriott Magnificent Mile Downtown 540 N. Michigan Ave, Chicago, IL 60611

International Forging Congress 2020 will end with a Closing Banquet on September 21, 2020 at the Marriott Magnificent Mile Downtown in the Chicago Ballroom. The IFC 2020 Closing Banquet will feature a duo-plated, three course dinner; unlimited beer and wine; and two performances by Chicago-based entertainer Dakota Horvath and The City Lights Orchestra. The Chicago Ballroom is located on the fifth floor of the Marriott Magnificent Mile Downtown. This is the same meeting space as Presentation Room A and the Exhibit Hall during the Congress. The banquet will begin at 6:30 p.m. and Dakota started his career covering Frank Sinatra at the age of five at Mickey Rourke’s Club in Miami. Sinatra invited him back stage when he was eight. It was written about in the “The National Enquirer” magazine. Sinatra told Dakota, “You’ve got it kid” and handed him his orange handkerchief from his vest pocket before he went on stage. Dakota has been tributing Sinatra ever since – from the “Legends in Concert” in Vegas, to Brad Pitt and Jennifer Aniston’s wedding in LA, to wrapping one year at The Four Queens Casino in Vegas inThe Broadway Rat Pack. Though Dakota started out his career covering Frank Sinatra, today he has established himself as a crossover artist who sings multiple genres of music including jazz, pop, funk soul and R&B. end at 9:30 p.m. About Dakota:

At the IFC 2020 Closing Banquet Dakota will perform with The City Lights Orchestra, a sought after group of entertainers who have appeared with other top notch national musicians including Ray Charles, Mel Torme, Paul McCartney and many others.

Register for IFC 2020 Registration is now open for IFC 2020. For immediate registration, better selection of plant tours and faster confirmation, register online by clicking here . If you have any questions about registration or to submit a paper registration, please contact Kathy Edwards at kathy@forging.org or (216) 781-6260. Sponsorship &Advertising Opportunities IFC 2020 is a unique opportunity to gain exposure to a global audience of potential customers. Take your participation to the next level by leveraging one of our sponsorship and branding opportunities. Make an impact by showcasing your company to the key decision-makers in the global forging industry. Click here to view or download the IFC 2020 Sponsorship Brochure. Advertising opportunities are also available. If you would like to advertise in the Official IFC 2020 Program Guide, click here to view or download information on available advertising opportunities. For more information on sponsorship and advertising opportunities, please contact Sarah Ploskonka at sarah@forging.org or (216) 781-6260.

FIA MAGAZINE | FEBRUARY 2020 12

INDUSTRY NEWS & CALENDAR

Plant Tours

Tour 1: Chicago Plant Tours A Tuesday, September 22, 2020 8:30 a.m. Depart Marriott Magnificent Mile Downtown 9:30 a.m. Arrive SpringHill Suites by Marriott Chicago Naperville 10:30 a.m. Departs SpringHill Suites by Marriott Chicago Naperville 11:00 a.m. Arrive Forge Resources Group 1:00 p.m. Depart Forge Resources Group 1:30 p.m. Arrives at Topgolf Lunch &Topgolf Activity 4:00 p.m. Depart Topgolf 4:15 p.m. Arrive SpringHill Suites by Marriott Chicago Naperville Dinner on own Wednesday, September 23, 2020 8:30 a.m. Depart SpringHill Suites by Marriott Chicago Naperville 9:00 a.m. Arrive Fox Valley Forge Co. 11:00 a.m. Depart Fox Valley Forge Co. 11:30 a.m. Lunch at Sullivan’s Steak House 1:00 p.m. Depart Sullivan’s Steak House 2:00 p.m. Arrive Finkl Steel 4:00 p.m. Depart 5:00 p.m. Arrive SpringHill Suites by Marriott Chicago Naperville Dinner on own registration fee for shared hotel rooms. Protective eyewear, hearing protection and hard hats will be provided. Tour 2: Chicago Plant Tours B Tuesday, September 22, 2020 8:00 a.m. Depart Marriott Magnificent Mile Downtown 8:30 a.m. Arrive Marriott Chicago O’Hare 10:30 a.m. Depart Marriott Chicago O’Hare 10:45 p.m. Arrive Scot Forge, Franklin Park 12:15 p.m. Depart Scot Forge, Franklin Park 12:45 p.m. ArriveThe Saddle Room 2:30 p.m. Depart The Saddle Room

Topgolf

Sullivan's Steakhouse

Note: Plant Tour 1 registration includes motorcoach transportation from the Marriott Magnificent Mile Downtown to the SpringHill Suites by Marriott Chicago Naperville; two nights at the SpringHill Suites by Marriott Chicago Naperville (one hotel room); motorcoach transportation during plant tours; lunch at Topgolf; the Topgolf activity; and lunch at Sullivan’s Steak House. There will be no reduction in

The Saddle Room

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INDUSTRY NEWS & CALENDAR

2:45 p.m. 4:45 p.m. 5:25 p.m.

Arrive Elgin Sweeper Co. Depart Elgin Sweerper Co.

Arrive Marriott Chicago O’Hare Dinner on own

Wednesday, September 23, 2020 9:30 a.m.

Depart Marriott Chicago O’Hare

10:15 a.m. 12:15 p.m. 12:45 p.m.

Arrive Cornell Forge Co. Depart Cornell Forge Co.

Lagunitas Brewing Company

Arrive Lagunitas Brewing Company Lunch & Brewery Tour Depart Lagunitas Brewing Company Dinner on own

3:00 p.m.

Note: Plant Tour 2 registration includes motorcoach transportation from the Marriott Magnificent Mile Downtown to the Marriott Chicago O’Hare; two nights at the Marriott Chicago O’Hare (one hotel room); motorcoach transportation during the plant tours; lunch at The Saddle Room; lunch at Lagunitas Brewing Company; and the Lagunitas Brewing Company tour activity. There will be no reduction in

registration fee for shared hotel rooms. Protective eyewear, hearing protection and hard hats will be provided. Tour 3: Los Angeles Plant Tours Plant Tour registration does not include travel to Los Angeles, CA. Wednesday, September 23, 2020 5:00 p.m. Depart Residence Inn Long Beach Downtown Hotel 5:10 p.m. Arrive Parkers' Lighthouse Dinner at Parkers' Lighthouse 7:00 p.m. Depart Parkers' Lighthouse 7:10 p.m. Arrive Residence Inn Long Beach Downtown Thursday, September 24, 2020 9:00 a.m. Depart Residence Inn Long Beach Downtown Hotel 9:30 a.m. Arrive Weber Metals 11:30 a.m. Depart Weber Metals 12:00 p.m.

Parkers' Lighthouse

Arrive Boathouse on the Bay Lunch at Boathouse on the Bay Depart Boathouse on the Bay

1:30 p.m. 2:00 p.m. 4:00 p.m. 4:30 p.m.

Arrive AluminumPrecision Products, Inc. Depart Aluminum Precision Products, Inc. Arrive Residence Inn Long Beach Downtown Hotel Dinner on own

Boathouse on the Bay

Note: Plant Tour 3 registration includes two nights at The Residence Inn Long Beach Downtown, September 23 and September 24 (one hotel room); motorcoach transportation to Parkers' Lighthouse; dinner at Parkers' Lighthouse; motorcoach transportation during plant tours; and lunch at Boathouse on the Bay. There will be no reduction in registration fee for shared hotel rooms. Delegates are responsible for their own travel arrangements to Los Angeles, California. Protective eyewear, hearing protection and hard hats will be provided.

FIA MAGAZINE | FEBRUARY 2020 14

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International Forging Congress Presentation Abstracts

Sunday, September 20 Engineered Residual Stress Fields in Tool and Die Applications by Laser Shock Peening Stan Bovid, LSP Technologies Presentation Room A Laser shock peening is a novel technique for precisely engineering residual stress fields in components. It has been demonstrated by others that residual stress impedes fatigue cracking and extends tool life. In contrast to standard surface enhancement techniques that utilize bulk surface coverage, laser peening residual stress fields are precisely tailored in magnitude, depth and area. The design of these treatments is optimized through finite element methods and validated by in-service testing that outperforms other techniques. Recently, laser peening has been increasingly adopted into multiple tool and die applications: Cold rolling dies have benefited from an increased performance by reducing wear and Hertzian contact damage; die casting dies have benefited from reduced heat checking during thermal cycling; and injection molding dies have benefited from reduced fatigue cracking from pressure distributions. This presentation includes background information on the process, examples of residual stress field engineering, and real-world examples of laser peening improving service life. Innovative High Performance Tool Steels for Hot-Forging Applications Michael Hirtler, voestalpine BÖHLER Edelstahl Presentation Room B The increasing complexity of hot-forged components such as near net-shaped parts poses various challenges to forging-die materials. Hot-work tool steels have to show excellent mechanical and thermo physical properties to withstand the complex loading situation during the different forging processes and to lead to a high tool lifetime. Wear, plastic deformation and thermal and mechanical fatigue are considered as the typical damage mechanisms in such tools. To reduce those effects and to decrease the tooling costs the tool steel material requires an optimal combination of hardness, toughness, ductility, hot wear resistance, thermal conductivity and other properties. Over the years a lot of tool steel producers tried to improve these properties by modern alloy design and optimization in the production process. This presentation gives a resume about damage mechanisms, the property profile of new and innovative hot work tool steels and successful applications for forging tools.

Investigation of Directional Surface Topography In Forging Joseph P. Domblesky, Marquette University Presentation RoomC Although surface topography is known to affect forming behavior, relatively little has been written about the effect that anisotropic textures (i.e. directionality) have on friction and metal flow. In the current study, compression tests were conducted using steel and aluminum and H-13 platens which had isotropic and anisotropic surface textures respectively. Side pressing was performed to investigate planar metal flow while ring testing was used to measure friction factors. Results showed friction factors parallel to the platen lay were significantly lower than those in the perpendicular direction. This can be attributed to the tool lay effectively acting as a series of parallel macro-asperities which act to promote or inhibit flow at the tool-work interface. Side pressing showed that transverse metal flowwas sensitive to both platen roughness and lay orientation whereas longitudinal flow was only influenced by the latter. It is expected that the findings will help further an understanding of how anisotropic tool surfaces influence behavior in forging and illustrate their potential for optimizing metal flow. Lightweight Forging – A Success Story in Four Chapters Hans-Willi Raedt, Hirschvogel Automotive Group Presentation Room A Forging is a well-established manufacturing process especially for highly loaded components in large series applications. However, (steel) forgings seem to be undervalued as far as their lightweight potential is concerned. To demonstrate the lightweight design potential of forged components, the Lightweight Forging Initiative was formed in 2013. In the first phase, a passenger car was analyzed and a lightweight potential of 2kg was demonstrated. In 2015, the consortium showed 99kg of lightweight potential in a light duty vehicle. In the third multilateral industrial phase, a consortium of 39 companies from Europe, Japan and the US has come together. A hybrid split-axle-AWD car has been purchased and disassembled. Additionally, a truck transmission, propeller shaft and rear axle have been part of the project. All components have been analyzed for lightweight possibilities. It could be found that the application of modern forging technology or advanced steel materials can lead to drastic weight savings at comparatively low cost. Numerous examples will be shown to demonstrate the approach as well as concrete lightweight potentials. Additionally, a transmission weight analysis will be presented, with which the lightweight impact of more durable steels in transmission applications can be estimated.

FIA MAGAZINE | FEBRUARY 2020 15

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machine learning and numerous adaptive control solutions. A prototype cyber-physical forging process chain configured as a forging factory model was established within the scope of a project (acronym EMuDig4.0) at the author’s institute. The goal of this three years project was to develop and to elaborate valid solutions for integration of real and virtual components of production systems such as heating or measurement devices into the manufacturing sequence of forging under lab conditions. Both heating and two stage forging process in the model factory was designed to collect process and condition data delivered by inbuilt and external sensors. Online data storage and real-time data analysis were performed in a cloud-server to study adaptive and self-learning control strategies acting through an online assistance system used by the operator. Gained results of finite element simulation of forging process are used to train a neural networkmodel initially being used to calculate suitable feed forward adaptive control parameters (e.g. billet inductive heating temperature, ram displacement, etc.) based on input parameters (e.g. billet dimensions, actual tool temperatures). The developed prototype production system is capable of detecting, recording and separating scrap after the pre and final forming stages. Online work piece tracking, process parameters and product properties measured for successfully produced parts, as well as scrap, train the neural network further to increase the validity of the feed forward adaptive control solution. Digitalization and the potential capability of machine learning integrated into the controller system also facilitate a wide range of possibilities for predictive quality control of produced parts. Finite Element Modeling in Metal Forming and Forging Industries - What to Know andWhere to Apply Ming (Henry) He, The Timken Company Presentation Room B Applications of finite element analysis have tremendously reshaped the metal forming and forging industries in recent decades. Today, the finite element modeling is commonly employed as an effective tool to help engineers (1) in conceptual development or virtual prototyping phase precisely examine the behavior of the part to be formed so that the tools can be correctly designed and (2) in product improvement phase correctly and effectively identify the root causes of product defects and provide solutions. This presentation will present examples of the applications of finite element modeling to the forging, bulk and incremental forming, and thermal treatment processes for the above-mentioned purposes. Deformation plasticity theory, as the foundation of the metal forming modeling, is also briefly described. Die Set Construction Options for Post Forging Operations Steven Janiszewski, Superior Die Set Presentation RoomC A detailed look at die set construction options for post forging operations. Including the guiding elements, supported by FEA Analysis and field experience.

Metamorphic Manufacturing: Processing Pathways to Manufacture Custom Geometry Components with Tailored Microstructures Kester Clarke, Colorado School of Mines Presentation Room B The incorporation of digital controls and active closed-loop process parameter feedback into a flexible deformation processing station intrinsically affords the capacity to employ specific thermomechanical processing (TMP) pathways as a function of location within a component. This capacity will allow for the design and production of structural engineering components with the physical and mechanical properties tailored to a location within the part. Local microstructure control is, of course, possible in conventional processing, but without the flexibility to create unlimited numbers of unique component geometries in a single processing unit. The repeatability of digitally controlled processing equipment, the incorporation of in-situ monitoring of critical processing parameters, the ability to use any input material, and ultimately, the ability to use real-time microstructural development feedback supported by fundamental understanding and modeling, has the potential to revolutionize the way we think about component design and manufacturing. Advanced Remote Troubleshooting and Maintenance Techniques for Induction Heaters Joe Stambaugh, Ajax TOCCO Presentation RoomC This presentation will explore the advantages of remote internet access for induction heaters for the purpose of troubleshooting, maintenance implementation and programming. The safe and proper way to communicate remotely with the induction system and real-world examples of what can be accomplished remotely. Reduce downtime to a minimum via intelligent information gathering and troubleshooting analysis. Forging More Intelligently Through Workpiece Tracking, Adaptive Control andMachine Learning Mathias Liewald, Prof. Dr. and Celalettin Karadogan, Dr. Institute for Metal Forming Tech. University of Stuttgart Presentation Room A Hot forging reveals great potential for improvements in the spirit of Industry 4.0. The quality and stability of forging processes are conventionally evaluated after the heat treatment, based on produced properties of randomly selected work pieces. From this point of view, today’s state-of-the-art approach barely links the information collected from individually digitalized production processes and finished product properties. Hence, the root cause of scatter in the final product properties cannot be directly correlated with actual process parameters or any other process fluctuations. Contrary to this practice of today, the realization of work piece tracking enables the linking of such information from digitized raw materials, work piece properties and forging process parameters. This linked information is a large amount of process and property data bearing valuable correlations and constituting the base for

FIA MAGAZINE | FEBRUARY 2020 16

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The World's Biggest Pull-Down Hydraulic Closed-Die-Forging Press in the USA at Weber Metals and Recent Developments Taking Advantage of the Given Force at theWorldMarket Serdar Tuncel, SMS Group GmbH Presentation Room A The presentation gives an overview of the investment made on the world aerospace market in recent years. Otto Fuchs increased its capabilities of Ultra-Large Forgings with an SMS-built 540 MN (60,000 US tons) hydraulic pull-down press. This machine, located at Weber Metals Inc., Otto Fuchs’ US subsidiary, entered service in October 2018 and is the strongest press of its kind and the biggest closed-die forging press in America. The ability to exactly reproduce forging and stress relief operations allows to lower airframe weight by single-piece forgings replacing multiple part assemblies. This presentation also describes the technology-leading capabilities of the 540MN (60,000US-Tons) hydraulic forging press.The challenging technical solutions are presented which allow this unprecedented machine to operate quickly, accurately and safely. The New Trend in Hot and Warm Closed-Die Forging: Intelligent Lubrication Franck Belloy, Quaker Houghton Presentation Room B With automotive manufacturers asking for lighter alloys, high strength steels, conversion from hot to warm forging and weight reduction requiring Near Net Shape forging, the challenges are everywhere for forgers. And the lubricants used for years no longer meet today’s requirements. The solution to this increasingly difficult situation is Quaker Houghton’s intelligent lubrication. While most stayed focused on the same requirements for years such as cooling properties, lubricity, release, grip on the surface, viscosity and particle sizes, Quaker Houghton pushes the limit by creating new tests to complement historical testing and simulation software. Welcome to Quaker Houghton intelligent lubrication. Robotic Die &Component Welding System Chris Kerchkof, Eureka Welding Alloys Presentation RoomC This presentation will be a brief overview of the practices involved in forge die and component welding to date. What type of welding alloys are used for specific types of repairs to forging dies to address multiple types of failures inherent in the forging process as well as extend die life over that of virgin die block material? Also, what types of welding alloys are used for component repairs (Rams, Sow Blocks, Columns, Bases, Bolster Plates etc.)? We will introduce the Robotic Welding System, the next step in Forge Die & Component Welding. The presentation will cover the basics of how the systems software creates the welding programs in conjunction with set parameters given by a programmer. How to upload the welding programs into the robot controller and how the robot operator monitors welding jobs from that point until completion of a job. The presentation will go over the cost savings benefits of the welding system (material savings, welding time savings, machining time savings, etc.).

Comparison of Mechanical and Hydraulic Forging Presses Ken Setze, Schuler Incorporated Canton Presentation Room A Forging companies often have to determine whether to produce a given part on a mechanical or on a hydraulic press. As a leading press builder who is offering both solutions, we are comparing these concepts in terms of output, part geometry, portfolio, lot size and required flexibility. Also, we take a look at process requirements such as forming speed or duration of contact. Typical parts for production on mechanical and hydraulic presses will be shown and also a recommendation will be given which parts should not be made on one or the other concept. A brief overview of the major differences between both press types will explain the technical reasons behind the findings of this presentation. Many have heard the terms “Industry 4.0” and the “IIoT” and understand the general concept, but wonder what that means and how it applies to the Forging industry. Forging is different frommost manufacturing industries today; there are many old machines still in productive use today, and, forging is still as much an ‘art’ as it is ‘science’. So, what can IIoT, big data analytics, and cloud computing do for companies in this industry? How can you connect your old machines, and should you? What benefits can you and should you expect? Every manufacturing industry in North America faces the same problem of competition from low-cost regions, escalating environmental regulations, a growing skills shortage, and attracting young people to the industry. Learn how other industries have leveraged IIoT technologies to face these common challenges, using data to not only improve their processes but also to engage their people, and how these technologies and ideas can be applied effectively in this industry. Paul Hogendoorn has over 30 years of experience across many industry sectors helping manufacturers apply new technology for the purpose of connecting to machines and with people. The IIoT is about giving your people better tools. Applying Non-Destructive Examination Methods to Forge Presses Ronald P. Manganello, Carlesa NDE Services Presentation RoomC This presentation will discuss the application of nondestructive examination to forge presses and how it can benefit operations. Presentation content will cover preparation and planning, necessary access to critical components, safe application of nondestructive examination procedure, and why regular nondestructive examination is important to mitigate and manage the risk of press failure. Bringing the IIoT to Forging Forefront Paul Hogendoorn, FreePoint Technologies Presentation Room B

FIA MAGAZINE | FEBRUARY 2020 17

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Hot Forging Die Steel Review and Modeling of Cost Reduced Solutions Manuel Roman, Manuel Arean, Salvador Perez, CIE Automotive Presentation Room A Hot working tooling steel selection, post processing route and resulting parameters are factors affecting the performance of the tooling in service conditions. Due to the performance of the tooling costs of operation vary throughout the project life. Background studies in this field on the latest years are reviewed as a starting point to review possible methodologies for wear analysis and die life optimization. Simulation, lab tests and visual inspection capacities are discussed. To establish a model and optimizing the current solution for a specific process, a design of experiments is used. This design of experiments includes raw materials from key manufacturers of tooling steel, different processing routes to achieve initial blocks, machining, heat treatment and surface treatment process on the imprints. The performance is measured with standardized tests for finishing conditions, mechanical tests and metallurgic results. Visual inspection on die surface are included to help in process decision. Solutions are tested under different forging process conditions and performance indicators are obtained. Through statistical analysis these elements are included in a regression model with the aim of obtaining alternatives for material selection, processing conditions and in process parameters for hot forging with reduced cost of operation and extending time for batch change and tool renewal. How Virtual Process Manufacturing Will Meet Today's and Tomorrow's Challenges in the Field Of Aluminum Forging Nicolas Poulain, Transvalor Americas Corp. Presentation Room B Forging is an essential manufacturing process as it combines unbeatable advantages such as high component strength with the possibility of mass production. However, challenges such as light weighting have emerged and drive today’s demand for extensive use of aluminum alloys. This presentation aims at demonstrating how virtual manufacturing using FORGE® software provides crucial guidance to process and design engineers to improve production of high-performance forged components.The presentation focuses first on the material flow challenges in the context of aluminum forging sequence. Hand-picked examples show the benefits of simulation to detect forming defects and guarantee optimum grain flow. In the second part, the presentation focuses on the prediction of the final mechanical properties. Heat treatment is crucial to meet the final mechanical properties required by customers. Treatments such as solution treatment, quenching and aging are simulated to predict accurately the outcome. Based on the implementation of several research works on Quench Factor Analysis (QFA) and Shercliff Ashby models, simulation results will be presented and discussed.

Isostatic Forging -The Fit with Other Forging Processes Robert M. Conaway, Isostatic Forging International Presentation RoomC Isostatic Forging (IF) is the use of forming pressure in the yield, flow stress, or rapid creep, range of forming pressures. IF processes have virtually no practical limits on pressure applied and the temperature used. IF is generally regarded as a hot isostatic pressing (HIP) process, but now quite different. This paper will present the IFI view of how IF fits in with the forging industry technologies. ModernDesign Solutions of ForgingDevices for Forging Ingots and Blanks using Four Dies on Hydraulic Forging Presses Sergey Kuralekh, Lazorkin Engineering LLC Presentation Room A Three decades of hands-on experience in operation and design development of four-die forging devices (FDFD) under various industrial conditions on a variety of hydraulic presses proved that in every particular case and with a view to particular production needs, an individual approach is required to select both the proper FDFD design and the proper forging technology. The main selection criteria for proper device design and forging technology are: high production output, which should be significantly higher as compared to existing production technology output; improved metal quality and quality of products (in terms of dimensional accuracy and surface quality); cutback of the whole production cycle extent due to reduction of forging cycle, heating period and auxiliary operations duration; higher good metal yield. The paper describes new FDFD design solutions and new technologies, which meet these criteria for solving various technological tasks. It is also shown which changes to the technological process can be eventually required to gain the maximum benefit from using the FDFD. This paper also provides an overview of the similar forging equipment from other companies and a comparison of its functionality with FDFDs of our patented design. Newest Developments in Ring Rolling Robert Bolin, SMS Group Inc. Presentation Room B Recently there have been some major developments in ring rolling machine design that reduce cost, greatly improve efficiency and provide real time dimensional information during the rolling process. Our paper will introduce the concept of compact hydraulic systems as applied to ring rolling machines. The compact hydraulic design eliminates the need for a central hydraulic station, reduces installation costs and drastically improves energy efficiency. Our paper will also address advances in real time laser measuring systems that constantly monitor the ring profile during rolling and comparing it with the ideal shape allowing corrective action to be taken before the part becomes unusable.

FIA MAGAZINE | FEBRUARY 2020 18