February 2020 Volume 2

FORGING RESEARCH

therefore material mechanical properties after DFIQ, will be further improved in cases when the part requires additional heat treatment (for example carburizing, carbo-nitriding, etc.). Summary of DFIQBenefits for the Forging Industry The DFIQ process can be used successfully to produce microstructures and mechanical properties that meet product requirements. Strengths and hardness values of the DFIQ forgings were acceptable in all cases. Strength properties tended to be higher for DFIQ-treated forgings, most likely due to a higher cooling rate during the IQ process. Applicability of the DFIQ process is subject to the hardenability of the steel being used, part geometry, and manufacturing steps that follow the hot forging operation. Material microstructures of the production DFIQ forgings appears to be similar to that of the forgings after a conventional post-forging heat treatment, and in some cases, the DFIQ microstructure was found to be slightly coarser than the conventionally processed forgings. Use of the DFIQ process results in tremendous energy and cost saving by eliminating one or more reheat steps prior to final heat treatment, including the elimination of the use of environmentally unfriendly and hazardous quench oil and associated costs, and, in some cases, by completely eliminating a post-forging heat treatment process. The latter, in turn, results in significant reduction of the production lead time--up to 8 days for some parts. Figure 2 presents a current and proposed manufacturing process flow chart for one of the parts subjected to the DFIQ process. Additionally, the DFIQ process enables the substitution of lower alloy steels for high alloy steels, resulting in significant material cost savings. As a result of hands-on trials with the DFIQ unit at their production facilities, multiple forging companies are considering installing production DFIQ units . Participating forge shops realized annual saving from $400k to $700k and an ROI of 12 to 18 months. This project is ongoing and additional companies have expressed interest The DLA-funded Procurement Readiness Optimization--Forging Advanced Systems and Technologies (PRO-FAST) program supports the advancement of forging manufacturing technologies and DOD-focused supply chain research and development. Significant project requirements include participant cost-share, demonstrated relevance to DLA supply chain readiness and technology transition to the U.S. forging industry at large. If your company is interested in collaborating with FDMC on a research project, please contact FDMC Executive Director, Polly Graham, at (843) 760-3375 polly.graham@ati.org , or FDMC Project Manager, Dekland Barnum, at (843) 760-3538 dekland.barnum@ati.org . For specific questions on this project and how your company can test the DFIQ unit at your facility please contact Michael Aronov at (440) 542-0821 m.a.aronov@sbcglobal.net . in the technology. About FDMC

References. 1. N.I. Kobasko, M.A. Aronov, J.A. Powell and G.E. Totten, Chapter on “Intensive Water Quenching of Steel,” ASM Handbook “Steel Heat Treating Fundamentals and Processes,” 2013. 2. N.I. Kobasko, M.A. Aronov, J.A. Powell and G.E. Totten, “Intensive Quenching Systems: Engineering and Design,” ASTM, 2010. ■

Figure. 1. Portable 600-gallon DFIQ system.

Figure. 2. Manufacturing process flow chart.

Dr. Michael Aronov CEO of IQ Technologies, Inc.

Dekland Barnum, FDMC Project Manager

FIA MAGAZINE | FEBRUARY 2020 52