November 2023 Volume 5

EQUIPMENT & TECHNOLOGY

Hot Isothermal Forging (HIF): Meeting Industry Demands with an Innovative Solution By Dr. Serdar Tuncel, Axel Roßbach, and Cihangir Demirci

In the world of advanced manufacturing, the emergence of isotherm forging plants marks a significant milestone. This leading-edge technology is designed to manufacture workpieces with near-net shape precision, all within a controlled, constant high-temperature environment. The advantage of this process lies in its execution under vacuum conditions, with both the tools and workpieces maintained at constant forging temperature. To date, the complete isotherm forging lines within the industry have been developed by the aerospace industry suppliers themselves. They used their own knowledge to meet the certification requirements of aircraft turbines and aerospace industry material qualities. These suppliers procured the individual units such as the isotherm forging press, vacuum chamber, and heating unit as well as the isotherm tools themselves to develop the entire interfaces. SMS group is well-known as a full-line supplier. Recently, its engineers brought together ideas and technologies from different areas of the company and have come up with a new solution. Elevating Industry Standards through Integration With more than 150 years of forging press equipment experience, SMS group has combined the proven vacuum technology used in secondary and tertiary metallurgy, which is standard in these isothermal forging plants. The integration of the tool tower (die stack) and state-of-the-art heating technology, along with the process know-how of experienced engineers has produced an optimal system ready to accommodate a diverse range of future materials. This new approach eliminates the need for complex interfaces. Compelling Investment Factors Based on valuable feedback from our customer base, established sectors like aerospace and energy require components capable of withstanding elevated mechanical and thermal stresses. Meeting these requirements involves the capability to produce large components using innovative materials. This emphasizes the importance of cost-effective solutions that result in substantial savings, making isothermal forging plants a smart investment decision. Benefits and Features SMS group has developed a complete Hot Isothermal Forging (HIF) line seamlessly integrated without the need for interfaces.

This innovative approach builds upon established and time-tested technologies. Key features of the HIF-line: • Precise forging operations • Strict temperature control within a narrow range • Prevention of redox reactions • Elimination of potential negative material properties such as macrostructure and micro-crack formation With the added advantage of stable production within the forging process, the reliable and consistent components result in safe and rapid certification of processes, resulting in lower costs for the aerospace industry. In the HIF-line process, a stable synchronization of temperatures between the workpiece and the dies is maintained throughout the entire forging procedure. Achieving this balance is made possible through the use of vacuum heating furnace technology, which heats both the upper and lower dies and the workpiece. (Fig.1). • Optimization of the metallurgical parameters • Enabling the easier production large turbine discs • Full automation

Fig. 1: Die stack heating at “HIF-line.”

FIA MAGAZINE | NOVEMBER 2023 14