May 2021 Volume 3

FORGING RESEARCH

However, the recent focus on manufacturing increasingly critical parts by metal AM, augmented by successes with metal AM casting molds, injection molding tooling, extrusion dies, and hot metal stamping dies show the potential for forging die fabrication by metal AM. The research and development community has been exploring possibilities of manufacturing smart tooling and forging dies [7] with conformal cooling channels and embedded sensors to improve forging processes, quality of forgings, and cost and lead time reduction. Laboratory experiments show a 300% increase in production speed of a hot extrusion process using conformal cooling channels produced by metal AM in extrusion dies [8, 9]. Also, there are mounting evidences for the use of metal AM to insert conformal cooling channels for fabrication of hot stamping die [10] and injection molding tooling [11] to reduce forming cycle time and life cycle cost. The basic mechanical properties of die material at ambient and high temperatures havebeen shown tomatch those of forgingdiematerials when manufactured and tested in a laboratory environment. In order to utilize metal AM for forging die manufacturing, prototype forging die fabrication and associated forging trials need to be accomplished to achieve required readiness for implementation of the technology. The evidences in maturation of manufacturing technologies and availability of commercial machines indicate it is possible to close the existing gaps and prepare for manufacturing maturation and risk management for future implementation in production environment. Since there are substantial laboratory and some industrial evidences for utilizing metal AM for forging die fabrication, the associated risk is low. Therefore, it is necessary to undertake TMRR and EMD for production deployment and sustainment via demonstration of low and full rate production. Future Outlook The technology and manufacturing readiness levels, along with the maturity shortfalls as discussed above, warrant prototype forging die fabrication using metal AM in the near future. It is anticipated that the TMRR and EMD will be conducted in collaboration with forging industry supply chain and metal AM industry. A prototype demonstration plan for forging die fabrication in production environment will be prepared as part of this project to address the technological and manufacturing shortcomings. Work is underway and US forging companies, along with the die fabrication supply chain, are being solicited to participate and contribute to develop the demonstration plan. FIA has established a new Die Fabrication Committee to help develop the forging die fabrication demonstration plan. FIA member companies are encouraged to actively participate by contacting James Warren, FIA President and CEO, at jwarren@forging.org. About FDMC 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. The

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, Charles Edens, at 843-760-3376 charles.edens@ati.org, or FDMC Project Manager, Dekland Barnum, at 843-760-3538 dekland.barnum@ati.org. For specific questions on this project please contact Prabir Chaudhury at 480-577-0772 prabir.chaudhury@external.ati.org. This research is sponsored by the DLA-Troop Support, Philadelphia, PA and the Defense Logistics Agency Information Operations, J68, Research &Development, Ft. Belvoir, VA. References 1. Chaudhury, P. K. and Barnum, D. D. H. Additive Manufacturing for Forging Die Fabrication. FIA Magazine. 2020, Vol. 2, August, pp. 56-57. 2. GAO Best Practices. Technology Assessment Readiness Guide: Best Practices for Evaluating the Readiness of Technology for Use in Acquisition Programs and Projects: US Government Accountability Office, 2020. GAO-20-48G. 3. OSD Manufacturing Technology Program. Manufacturing Readiness Level (MRL) Deskbook. s.l. : US Department of Defense, 2018. 4. Chaudhury, P. K. Additive Manufacturing (AM) for Forging Die Fabrication Technology Readiness Assessment (TRA) Report: Forging Defense Manufacturing Consortium (FDMC), 2020. 5. Wohlers, T., et al. Wohlers Report 2020: 3D Printing and Additive Manufacturing Global State of the Industry. Fort Collins, CO : Wohlers Associates, 2020. 6. Chaudhury, P. K. Additive Manufacturing (AM) for Forging Die Fabrication Manufacturing Readiness Level (MRL) Report. 2020. 7. Cao, J., et al. Manufacturing of advanced smart tooling for metal forming. 2019, CIRP Annals - Manufacturing Technology, Vol. 68, pp. 605 - 628. 8. H€olker-J€ager, R. and and Tekkaya, A.E . Additive manufacture of tools and dies for metal forming. [ed.] M. Brandt. Laser Additive Manufacturing: Materials, Design, Technologies, and Applications. Elsevier, 2017, pp. 439 - 464. 9. Pelaccia, R., et al. Efficiency of Conformal Cooling Channels Inserts for Extrusion Dies. 2020. Procedia Manufacturing. Vol. 47, pp. 209 - 216. 10. Arrizubieta, J. I., et al. Case Study: Modeling of the cycle time reduction in a B-Pillar hot stamping operation using conformal cooling. 2019. Procedia Manufacturing. Vol. 41, pp. 50 - 57. 11. Davis, W., et al. An appraisal on the sustainability payback of additively manufactured molds with conformal cooling. 2020. Procedia CIRP. Vol. 90, pp. 516 - 521. ■

FIA MAGAZINE | MAY 2021 87