November 2024 Volume 6

FORGING RESEARCH

Improvements of H13 Forging Tool Life Through TiC Reinforced Inconel 6 Lehigh University Industry Partners: American Axle & Manufacturing & Scientific Forming Technologies The goal of this project is to increase the life of hot forging tooling by applying TiC reinforced Inconel 625 coating via the selective laser melting process on the H-13 tool steel. The manufactured coupons under various processing conditions will be analyzed for the best mechanical and tribological performance. The best SLM condi tion will be selected to fabricate compression samples to be used to establish the flow stress material model as a function of tempera ture, strain, and strain rate. This model will be available for FEM numerical simulation of the hot forging process using DEFORM 3D in the next stage of the project. Predicting Site-Specific Microtexture During The goal of this project is to develop a computationally inexpensive framework capable of predicting the site-specific evolution of micro texture in titanium alloy forgings. Manufacturing Automation Cell (MAC) Project The goal of this Manufacturing Automation Cell (MAC) project is to serve as a catalyst and advance the field of manufacturing educa tion. This project aims to increase the number of qualified advanced manufacturing technicians by working collaboratively with industry partners to develop work-based learning opportunities. The project will take a multilayered approach through innovative training methods, real world hands-on projects and lab-based manufacturing opportunities. This will enable educators and practitioners to more effectively develop critically needed skilled workers in one of the most rapidly growing sectors of manufacturing. Intensive Quenching of Die Steels: Compressive Stresses The University of Akron Industry Partner: Viking Forge The goal of this project is to advance the state of the art in quench processing of high carbon high-alloy tool and die steels. Advanced tool steels are of interest to forgers because the life of the punch or die is critical when forging components. Failures in dies occur due to fatigue (mechanical and thermal), deformation, cracking, chipping and erosion. We aim to study heat treatment of common tool steels used in the forging industry to improve die life through improved surface properties through introduction of beneficial stresses. Blackhawk Technical College Industry Partner: Scot Forge Forging of Ti-6Al-4V University of Florida Industry Partner: ATI

Predicting The Occurrence of Central Burst During Open Die Forging of High Strength Steels Université du Québec Industry Partners: Transvalor & Finkl Steel The goal of this project is to quantify the impact of various open die forging parameters on the occurrence of centerline burst during open die forging of large size forgings. This will be achieved through a combination of finite element modeling using the FEM code FORGE NXT4, and experimental work using a Gleeble 3800 ther momechanical simulator and its MaxStrain module that is specially designed for simulating the forging process, as well as, the 1000 tons instrumented hot forging press. Assessing Deviations from Flow Stress Models at the Extremes of the Aluminum Forging Range University of Cincinnati Industry Partner: Queen City Forging The goal of this project is to train two undergraduate research assis tants under the guidance of a team of three UC metallurgical faculty (Dr. Matt Steiner, Dr. Eric Payton, and Dr. Chris Calhoun) to run compression tests on a Gleeble 3500 thermomechanical testing system to analyze the strain rate sensitivity, via strain rate jump testing, and establish the conversion of mechanical work into heat to characterize the variation in mechanical work partitioning and adiabatic correction factors in aluminum alloy 2618. The incorpo ration of functions for these parameters will then be compared to the effect of assuming the parameters are constant in flow stress modeling, in the context of a finite element process model of mate rial flow during closed-die forging. 50-ton Forging Demonstration/ Experimental Press Build Marquette University Industry Partners: Walker Forge & Estwing The goal of this project is to build a 50-ton hydraulic press suitable for improved forging education and research purposes. This increase in capacity is critically needed to allow us to expand our research to include steel closed-die forgings. Design, procurement, and assembly of the press will be performed by Ross Crowley with the aid of one or more undergraduate students. Numerical Modeling of Tooling Improvements for Forging Processes Lehigh University Industry Partners: Scientific Forming Technologies & Universal Stainless The goal of this project is to increase the life of hot forging tooling by applying TiC-reinforced Inconel 625 coating via the selective laser melting process on the H-13 tool steel. Based on the already performed and ongoing experimental studies supported by FIERF the Lehigh team plans to apply the materials models built in ongoing research to DEFORM 3-D platform and perform numerical simu lation of pressing and hammering processes to evaluate the new

FIA MAGAZINE | NOVEMBER 2024 64