February 2022 Volume 4

FORGING RESEARCH

Figure 4: Midplane cut of final tooling and preform strain distribution showing prediction of adequate strain for closing micro-porosity from the casting result.

Forging is proposed as an added processing step to enhance the critical sections of a cast product. There were no detrimental effects observed in these studies to casting properties after forging, and the mechanical properties generally increased through forging. This effect was attributed to the reduction in pore cluster size as compared to the equivalent cast section. This effect is also observed from HIPing (Hot Isostatic Pressing). HIPing is considered to be the gold standard for densifying steel castings, though forging provides an alternative process without the size constraints of HIPing. Forging also allows the option to focus only on critical areas when the entire cast part does not need to be treated. Comparison of the reduction in area between cast+HIPed and cast+forged steel in this study showed forged steel properties are equal or better to those of HIPed steel. Additional opportunities beyond the GET component could include part consolidation of multiple forging components, such as assemblies of universal joints or power transmitting gear sections. Example candidates for this approach include railroad coupler components, powertrain components of large mining or defense vehicles, vehicle track shoe components, or other critical components. Another potential application for this technology specific to the military is munitions. Munitions are produced from a specialty material that is not commonly available and is difficult to forge because of the high carbon and alloy content, also making the material expensive. Using a cast preform in this application would provide this specialty material in an efficient shape to reduce cost, increase availability, and potentially improve performance. The Cast Preforms technology is targeting new or specialty parts that require specific alloys or complicated geometries with enhanced properties and is one example of SFSA’s many ongoing research opportunities under our Steel Performance Initiative (SPI) funded by the DLA. SPI organizes collaboration between steel industry leaders and university researchers to answer the DoD’s call for

innovation by developing and implementing technology. SFSA is interested in partnering with FIA members to pursue research that will directly benefit the forging industry and retain domestic world-class capability through advanced technology and processing implementation for both commercial and defense needs. Please reach out to Alexa Smith (asmith@sfsa.org) to discuss any potential ideas or go to steelperformance.org to learn more. This research is sponsored by the DLA-Troop Support, Philadelphia, PA, and the Defense Logistics Agency Information Operations, J68, Research & Development, Ft. Belvoir, VA and conducted under Advanced Technology International’s Improved Forging Acquisition Manufacture and Materials (IFAMM) Program, with collaboration from University of Alabama, University of Alabama at Birmingham, and Steel Founders’ Society of America. Alexa Smith Steel Founders' Society of America

Phone: 815-526-0856 Email: asmith@sfsa.org

FIA MAGAZINE | FEBRUARY 2022 71