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Sample records for forging process parameters

  1. Influence of Processing Parameters on Grain Size Evolution of a Forged Superalloy

    NASA Astrophysics Data System (ADS)

    Reyes, L. A.; Páramo, P.; Salas Zamarripa, A.; de la Garza, M.; Guerrero-Mata, M. P.

    2016-01-01

    The microstructure evolution of nickel-based superalloys has a great influence on the mechanical behavior during service conditions. Microstructure modification and the effect of process variables such as forging temperature, die-speed, and tool heating were evaluated after hot die forging of a heat-resistant nickel-based alloy. Forging sequences in a temperature range from 1253 to 1323 K were considered through experimental trials. An Avrami model was applied using finite element data to evaluate the average grain size and recrystallization at different evolution zones. It was observed that sequential forging at final temperatures below 1273 K provided greater grain refinement through time-dependent recrystallization phenomena. This investigation was aim to explore the influence of forging parameters on grain size evolution in order to design a fully homogenous and refined microstructure after hot die forging.

  2. An Approach to Optimize Size Parameters of Forging by Combining Hot-Processing Map and FEM

    NASA Astrophysics Data System (ADS)

    Hu, H. E.; Wang, X. Y.; Deng, L.

    2014-11-01

    The size parameters of 6061 aluminum alloy rib-web forging were optimized by using hot-processing map and finite element method (FEM) based on high-temperature compression data. The results show that the stress level of the alloy can be represented by a Zener-Holloman parameter in a hyperbolic sine-type equation with the hot deformation activation energy of 343.7 kJ/mol. Dynamic recovery and dynamic recrystallization concurrently preceded during high-temperature deformation of the alloy. Optimal hot-processing parameters for the alloy corresponding to the peak value of 0.42 are 753 K and 0.001 s-1. The instability domain occurs at deformation temperature lower than 653 K. FEM is an available method to validate hot-processing map in actual manufacture by analyzing the effect of corner radius, rib width, and web thickness on workability of rib-web forging of the alloy. Size parameters of die forgings can be optimized conveniently by combining hot-processing map and FEM.

  3. Parameter Optimization During Forging Process of a Novel High-Speed-Steel Cold Work Roll

    NASA Astrophysics Data System (ADS)

    Guo, Jing; Liu, Ligang; Sun, Yanliang; Li, Qiang; Ren, Xuejun; Yang, Qingxiang

    2016-01-01

    The forging of high-speed-steel (HSS) roll has always been a technical problem in manufacturing industry. In this study, the forging process of a novel HSS cold work roll was simulated by deform-3D on the basis of rigid-viscoplastic finite element model. The effect of heating temperature and forging speed on temperature and stress fields during forging process was simulated too. The results show that during forging process, the temperature of the contact region with anvils increases. The stress of the forging region increases and distributes un-uniformly, while that of the non-forging region is almost zero. With increasing forging time, Z load on anvil increases gradually. With increasing heating temperature or decreasing forging speed, the temperature of the whole billet increases, while the stress and Z load on anvil decrease. In order to ensure the high efficiency and safety of the forging process, the heating temperature and the forging speed are chosen as 1160 °C and 16.667 mm/s, respectively.

  4. Effects of Forging Process Parameters on Microstructure Evolution of Aluminum Alloy 7050

    SciTech Connect

    Yi Youping; Shi Yan; Yang Jihui; Lin Yongcheng

    2007-04-07

    The objective of this work is to investigate the behavior of microstructure evolution of aluminum alloy 7050 under the condition of different forging process parameters by means of combining materials physical model with finite element code. For the purpose of establishing constitutive equation and physical model of microstructure evolution, the isothermal compression test were performed by machine Gleeble 1500 on the condition of temperatures ranging from 250 deg. C to 450 deg. C and constant strain rates of 0.01s-1, 0.1s-1, 1s-1 and 10s-1. The behaviors of microstructure evolutions of aluminum alloy 7050 under difference process parameters were studied by metallographic observations. The experiment results showed that recrystallization during forming process occurred at the critical strain and the volume fraction of recrystallization changed with the temperature and strain rate. According to the results of isothermal compression test, a constitutive equation and an empirical model of DRX were obtained. A finite element code DEFORM 3D was used to analyze the influence of different forging process parameters on the behavior of microstructure evolution in details. The present model and simulation method can be served as a useful tool to predict and control the properties and shape of aluminum alloy 7050 components during forging.

  5. Deformation processes in forging ceramics

    NASA Technical Reports Server (NTRS)

    Cannon, R. M.; Rhodes, W. H.

    1972-01-01

    The deformation processes involved in the forging of refractory ceramic oxides were investigated. A combination of mechanical testing and forging are utilized to investigate both the flow and fracture processes involved. An additional hemisphere forging was done which failed prematurely. Analysis and comparison with available fracture data for AL2O3 indicated possible causes of the failure. Examination of previous forgings indicated an increase in grain boundary cavitation with increasing strain.

  6. Large forging manufacturing process

    DOEpatents

    Thamboo, Samuel V.; Yang, Ling

    2002-01-01

    A process for forging large components of Alloy 718 material so that the components do not exhibit abnormal grain growth includes the steps of: a) providing a billet with an average grain size between ASTM 0 and ASTM 3; b) heating the billet to a temperature of between 1750.degree. F. and 1800.degree. F.; c) upsetting the billet to obtain a component part with a minimum strain of 0.125 in at least selected areas of the part; d) reheating the component part to a temperature between 1750.degree. F. and 1800.degree. F.; e) upsetting the component part to a final configuration such that said selected areas receive no strains between 0.01 and 0.125; f) solution treating the component part at a temperature of between 1725.degree. F. and 1750.degree. F.; and g) aging the component part over predetermined times at different temperatures. A modified process achieves abnormal grain growth in selected areas of a component where desirable.

  7. Forging process design for risk reduction

    NASA Astrophysics Data System (ADS)

    Mao, Yongning

    In this dissertation, forging process design has been investigated with the primary concern on risk reduction. Different forged components have been studied, especially those ones that could cause catastrophic loss if failure occurs. As an effective modeling methodology, finite element analysis is applied extensively in this work. Three examples, titanium compressor disk, superalloy turbine disk, and titanium hip prosthesis, have been discussed to demonstrate this approach. Discrete defects such as hard alpha anomalies are known to cause disastrous failure if they are present in those stress critical components. In this research, hard-alpha inclusion movement during forging of titanium compressor disk is studied by finite element analysis. By combining the results from Finite Element Method (FEM), regression modeling and Monte Carlo simulation, it is shown that changing the forging path is able to mitigate the failure risk of the components during the service. The second example goes with a turbine disk made of superalloy IN 718. The effect of forging on microstructure is the main consideration in this study. Microstructure defines the as-forged disk properties. Considering specific forging conditions, preform has its own effect on the microstructure. Through a sensitivity study it is found that forging temperature and speed have significant influence on the microstructure. In order to choose the processing parameters to optimize the microstructure, the dependence of microstructure on die speed and temperature is thoroughly studied using design of numerical experiments. For various desired goals, optimal solutions are determined. The narrow processing window of titanium alloy makes the isothermal forging a preferred way to produce forged parts without forging defects. However, the cost of isothermal forging (dies at the same temperature as the workpiece) limits its wide application. In this research, it has been demonstrated that with proper process design, the die

  8. Deformation processes in forging ceramics

    NASA Technical Reports Server (NTRS)

    Cannon, R. M.; Rhodes, W. H.

    1973-01-01

    The deformation processes involved in the forging of refractory ceramic oxides were investigated. A combination of mechanical testing and forging was utilized to investigate both the flow and fracture processes involved. Deformation studies of very fine grain Al203 revealed an apparent transition in behavior, characterized by a shift in the strain rate sensitivity from 0.5 at low stresses to near unity at higher stresses. The behavior is indicative of a shift in control between two dependent mechanisms, one of which is indicated to be cation limited diffusional creep with significant boundary enhancement. The possible contributions of slip, indicated by crystallographic texture, interface control of the diffusional creep and inhomogeneous boundary sliding are also discussed. Additional experiments indicated an independence of deformation behavior on MgO doping and retained hot pressing impurities, at least for ultrafine grained material, and also an independence of test atmosphere.

  9. Effect of the Process Parameters on the Formability, Microstructure, and Mechanical Properties of Thin Plates Fabricated by Rheology Forging Process with Electromagnetic Stirring Method

    NASA Astrophysics Data System (ADS)

    Jin, Chul Kyu; Jang, Chang Hyun; Kang, Chung Gil

    2014-01-01

    A thin plate (150 × 150 × 1.2 mm) with embedded corrugation is fabricated using the rheoforming method. Semisolid slurry is created using the electromagnetic stirring (EMS) system, and the thin plate is made with the forging die at the 200-ton hydraulic press. The cross sections and microstructures of the slurry with and without stirring are examined. To investigate the effect of the process parameters on the formability, microstructure, and mechanical properties of thin plate the slurry is subjected to 16 types of condition for the forging experiment. The 16 types included the following conditions: Whether the EMS is applied or not, three fractions of the solid phase at 35, 45 and 55 pct; two compression velocities at 30 and 300 mm s-1; and four different compression pressures—100, 150, 200 and 250 MPa. The thin plate's formability is enhanced at higher punch velocity for compressing the slurry, and fine solid particles are uniformly distributed, which in turn, enhances the plate's mechanical properties. The pressure between 150 and 200 MPa is an appropriate condition to form thin plates. A thin plate without defects can be created when the slurry at 35 pct of the solid fraction (f s) was applied at the compression velocity of 300 mm s-1 and 150 MPa of pressure. The surface state of thin plate is excellent with 220 MPa of tensile strength and 13.5 pct of elongation. The primary particles are fine over the entire plate, and there are no liquid segregation-related defects.

  10. Impedance analysis of forging process and strategy study on compliance for forging manipulator

    NASA Astrophysics Data System (ADS)

    Zhang, Pu; Yao, Zhenqiang; Du, Zhengchun

    2013-07-01

    In the field of heavy forging, there are numerous researches on deformation rule in forging process by FEM simulation, however, not many scholars take the equipment constraint and the mutual reaction load between the forging manipulator clamp and the forging blank into account, which will impact on safety of manipulator body and quality of forging blank. This paper presents an impedance model to describe the load and formulates compliance strategies correspondingly to reduce the mutual reaction load for forging manipulator. Firstly, an FEM model of forging process is built. Meanwhile, the clamp of forging manipulator is added to the model as movement constraint and interaction part between the manipulator and the forming process. Secondly, a typical forging process is simulated by changing the movement constraint, and then an impedance model is established to describe the relationship between the load and movement constraint. Finally, two kinds of compliance strategies are formulated according to the impedance model, one is called free compliance, and the other is initiative/passive compliance. The simulation results show that compliance strategies reduce the load amounting to 5 000 kN in z direction between the manipulator clamp and the forging blank obviously, which may lead to serious accidents, such as the capsizing of forging manipulator, the fracture of manipulator clamp, and so on. The proposed research simulates the more real forging process, gets the initiative/passive compliance strategy which is more simple and suitable to the real producing and better for forming a forging process planning and control system in the modern production, and improves the quality and efficiency of heavy forging.

  11. Modelling of the radial forging process of a hollow billet with the mandrel on the lever radial forging machine

    NASA Astrophysics Data System (ADS)

    Karamyshev, A. P.; Nekrasov, I. I.; Pugin, A. I.; Fedulov, A. A.

    2016-04-01

    The finite-element method (FEM) has been used in scientific research of forming technological process modelling. Among the others, the process of the multistage radial forging of hollow billets has been modelled. The model includes both the thermal problem, concerning preliminary heating of the billet taking into account thermal expansion, and the deformation problem, when the billet is forged in a special machine. The latter part of the model describes such features of the process as die calibration, die movement, initial die temperature, friction conditions, etc. The results obtained can be used to define the necessary process parameters and die calibration.

  12. Microstructural Evaluation of Forging Parameters for Superalloy Disks

    NASA Technical Reports Server (NTRS)

    Falsey, John R.

    2004-01-01

    Forgings of nickel base superalloy were formed under several different strain rates and forging temperatures. Samples were taken from each forging condition to find the ASTM grain size, and the as large as grain (ALA). The specimens were mounted in bakelite, polished, etched and then optical microscopy was used to determine grain size. The specimens ASTM grain sizes from each forging condition were plotted against strain rate, forging temperature, and presoak time. Grain sizes increased with increasing forging temperature. Grain sizes also increased with decreasing strain rates and increasing forging presoak time. The ALA had been determined from each forging condition using the ASTM standard method. Each ALA was compared with the ASTM grain size of each forging condition to determine if the grain sizes were uniform or not. The forging condition of a strain rate of .03/sec and supersolvus heat treatment produced non uniform grains indicated by critical grain growth. Other anomalies are noted as well.

  13. Improvements in the process of boss bar upset forging into a horizontal forging machine with the aim of joint knuckle forging quality improvement

    NASA Astrophysics Data System (ADS)

    Pankratov, D. L.; Nizamov, R. S.; Kharisov, I. Zh

    2016-06-01

    A new technique for tapered composing transition shaping has been put forward in the process of upset forging with the use of an experimental tool. The results of the upset forging process with the use of a new composing transition has been computer simulated.

  14. Process modelings and simulations of heavy castings and forgings

    NASA Astrophysics Data System (ADS)

    Li, Dianzhong; Sun, Mingyue; Wang, Pei; Kang, Xiuhong; Fu, Paixian; Li, Yiyi

    2013-05-01

    The Materials Process Modeling Division, IMR, CAS has been promoting for more than 10 years research activities on modeling and experimental studies on heavy castings and forgings. In this report, we highlight some selected achievements and impacts in this area: To satisfy domestic strategic requirements, such as nuclear and hydraulic power, marine projects and high speed rail, we have developed a number of casting and forging technologies, which combine advanced computing simulations, X-ray real time observation techniques and industrial-scaled trial experiments. These technologies have been successfully applied in various industrial areas and yielded a series of scientific and technological breakthroughs and innovation. Important examples of this strategic research include the hot-processing technologies of the Three Gorge water turbine runner, marine crankshaft manufacturers, backup rolls for hot rolling mills and the production of hundreds-ton steel ingot.

  15. First Results of Energy Saving at Process Redesign of Die Forging Al-Alloys

    SciTech Connect

    Pepelnjak, Tomaz; Kuzman, Karl; Kokol, Anton

    2011-05-04

    The contribution deals with eco-friendly solutions for shortened production chains of forging light alloys. During the die forging operations a remarkable amount of material goes into the flash and later on into chips during finish machining. These low value side products are rich with embedded energy therefore recycling or reprocessing could be very energy saving procedure.In cooperation with a die forging company a shortened reprocessing cycle has been studied starting from re-melting the forging flash and without additional heating to cast preforms for subsequent die forging. As such preforms have not as good formability characteristics as those done from extruded billets the isothermal forging process has been adopted. First results showed that without cracks and other defects the formability is sufficient for a broad spectrum of forgings.To improve the formability a homogenization process of cast preforms has been implemented. As the process started immediately after casting, amount of additional energy for heating was minimized. To reduce voids forging process was redesigned in a way to assure greater hydrostatic pressures in parts during forging. First results were promising therefore research is going towards improving processes without adding significantly more energy as it is needed for casting with homogenization and die forging.

  16. Material Behavior Based Hybrid Process for Sheet Draw-Forging Thin Walled Magnesium Alloys

    SciTech Connect

    Sheng, Z.Q.; Shivpuri, R.

    2005-08-05

    Magnesium alloys are conventionally formed at the elevated temperatures. The thermally improved formability is sensitive to the temperature and strain rate. Due to limitations in forming speeds, tooling strength and narrow processing windows, complex thin walled parts cannot be made by traditional warm drawing or hot forging processes. A hybrid process, which is based on the deformation mechanism of magnesium alloys at the elevated temperature, is proposed that combines warm drawing and hot forging modes to produce an aggressive geometry at acceptable forming speed. The process parameters, such as temperatures, forming speeds etc. are determined by the FEM modeling and simulation. Sensitivity analysis under the constraint of forming limits of Mg alloy sheet material and strength of tooling material is carried out. The proposed approach is demonstrated on a conical geometry with thin walls and with bottom features. Results show that designed geometry can be formed in about 8 seconds, this cannot be formed by conventional forging while around 1000s is required for warm drawing. This process is being further investigated through controlled experiments.

  17. Process Modelling of IN718 for Free Forging

    SciTech Connect

    Yoshida, Hiroaki; Hatta, Takeshi; Hironaka, Tomohisa; Isogawa, Sachihiro; Sekiguchi, Hideaki

    2007-05-17

    Ni based alloy IN718 is important material used for engine shafts, turbine disks of gas turbine engines. The grain refining of the IN718 becomes important because of the improvement of reliability. We have developed newly advanced {delta} process to obtain the grain of less than 22.5 {mu} m (ASTM No.8.0) even after solution treatment. Furthermore we have developed the microstructural prediction system of IN718 for the process modelling. In this paper, the advanced {delta} process and it's process modelling in the turbine disk forging were reported. As the result, we could obtain successful fine microstructure less than 22.5 {mu} m after solution treatment in turbine disk.

  18. A novel process for breakdown forging of coarse-grain intermetallic alloys

    SciTech Connect

    Semiatin, S.L. . Materials Directorate); McQuay, P.A. . Asian Office of Aerospace R and D); Seetharaman, V. )

    1993-11-01

    The objective of the present work was to develop a novel hot forging process for breakdown of high-temperature intermetallic alloys which exhibit dynamic recrystallization during hot working. During typical forging processes in hydraulic processes, be they based on isothermal or conventional approaches, the ram speed (or sometimes the effective strain rate) is held constant during the forging stroke. In the method introduced here, the ram speed is increased substantially during the forging stroke as the material recrystallizes to a finer-grained structure and its hot workability increases. By this means, fracture is avoided, grain size is reduced, and processing time is decreased, thus improving material quality and reducing cost. The material used to develop and demonstrate the novel forging process was the single phase gamma titanium aluminide, Ti-51Al-2Mn.

  19. Microstructure Modeling of a Ni-Fe-Based Superalloy During the Rotary Forging Process

    NASA Astrophysics Data System (ADS)

    Loyda, A.; Hernández-Muñoz, G. M.; Reyes, L. A.; Zambrano-Robledo, P.

    2016-06-01

    The microstructure evolution of Ni-Fe superalloys has a great influence on the mechanical behavior during service conditions. The rotary forging process offers an alternative to conventional bulk forming processes where the parts can be rotary forged with a fraction of the force commonly needed by conventional forging techniques. In this investigation, a numerical modeling of microstructure evolution for design and optimization of the hot forging operations has been used to manufacture a heat-resistant nickel-based superalloy. An Avrami model was implemented into finite element commercial platform DEFORM 3D to evaluate the average grain size and recrystallization during the rotary forging process. The simulations were carried out considering three initial temperatures, 980, 1000, and 1050 °C, to obtain the microstructure behavior after rotary forging. The final average grain size of one case was validated by comparing with results of previous experimental work of disk forging operation. This investigation was aimed to explore the influence of the rotary forging process on microstructure evolution in order to obtain a homogenous and refined grain size in the final component.

  20. Forging Advisor

    SciTech Connect

    Kerry Barnett

    2003-03-01

    Many mechanical designs demand components produced to a near net shape condition to minimize subsequent process steps. Rough machining from slab or bar stock can quickly and economically produce simple prismatic or cylindrical shapes. More complex shapes can be produced by laser engineered net shaping (LENS), casting , or forging. But for components that require great strength in mission critical applications, forging may be the best or even the only option. However, designers of these parts may and often do lack the detailed forging process knowledge necessary to understand the impact of process details such as grain flow or parting line placement on both the forging process and the characteristics of the forged part. Economics and scheduling requirements must also be considered. Sometimes the only viable answer to a difficult problem is to re-design the assembly to reduce loading and enable use of other alternatives.

  1. Approximate-model based estimation method for dynamic response of forging processes

    NASA Astrophysics Data System (ADS)

    Lei, Jie; Lu, Xinjiang; Li, Yibo; Huang, Minghui; Zou, Wei

    2015-03-01

    Many high-quality forging productions require the large-sized hydraulic press machine (HPM) to have a desirable dynamic response. Since the forging process is complex under the low velocity, its response is difficult to estimate. And this often causes the desirable low-velocity forging condition difficult to obtain. So far little work has been found to estimate the dynamic response of the forging process under low velocity. In this paper, an approximate-model based estimation method is proposed to estimate the dynamic response of the forging process under low velocity. First, an approximate model is developed to represent the forging process of this complex HPM around the low-velocity working point. Under guaranteeing the modeling performance, the model may greatly ease the complexity of the subsequent estimation of the dynamic response because it has a good linear structure. On this basis, the dynamic response is estimated and the conditions for stability, vibration, and creep are derived according to the solution of the velocity. All these analytical results are further verified by both simulations and experiment. In the simulation verification for modeling, the original movement model and the derived approximate model always have the same dynamic responses with very small approximate error. The simulations and experiment finally demonstrate and test the effectiveness of the derived conditions for stability, vibration, and creep, and these conditions will benefit both the prediction of the dynamic response of the forging process and the design of the controller for the high-quality forging. The proposed method is an effective solution to achieve the desirable low-velocity forging condition.

  2. 3D Finite Element Analysis of Spider Non-isothermal Forging Process

    NASA Astrophysics Data System (ADS)

    Niu, Ling; Wei, Wei; Wei, Kun Xia; Alexandrov, Igor V.; Hu, Jing

    2016-06-01

    The differences of effective stress, effective strain, velocity field, and the load-time curves between the spider isothermal and non-isothermal forging processes are investigated by making full use of 3D FEA, and verified by the production experiment of spider forging. Effective stress is mainly concentrated on the pin, and becomes lower closer to the front of the pin. The maximum effective strain in the non-isothermal forging is lower than that in the isothermal. The great majority of strain in the non-isothermal forging process is 1.76, which is larger than the strain of 1.31 in the isothermal forging. The maximum load required in the isothermal forging is higher than that in the non-isothermal. The maximum experimental load and deformation temperature in the spider production are in good agreement with those in the non-isothermal FEA. The results indicate that the non-isothermal 3D FEA results can guide the design of the spider forging process.

  3. 3D Finite Element Analysis of Spider Non-isothermal Forging Process

    NASA Astrophysics Data System (ADS)

    Niu, Ling; Wei, Wei; Wei, Kun Xia; Alexandrov, Igor V.; Hu, Jing

    2016-05-01

    The differences of effective stress, effective strain, velocity field, and the load-time curves between the spider isothermal and non-isothermal forging processes are investigated by making full use of 3D FEA, and verified by the production experiment of spider forging. Effective stress is mainly concentrated on the pin, and becomes lower closer to the front of the pin. The maximum effective strain in the non-isothermal forging is lower than that in the isothermal. The great majority of strain in the non-isothermal forging process is 1.76, which is larger than the strain of 1.31 in the isothermal forging. The maximum load required in the isothermal forging is higher than that in the non-isothermal. The maximum experimental load and deformation temperature in the spider production are in good agreement with those in the non-isothermal FEA. The results indicate that the non-isothermal 3D FEA results can guide the design of the spider forging process.

  4. Proposal to study stem forgings

    SciTech Connect

    Odegard, B.C.

    1982-06-25

    Reservoir designs consist of two primary features including the stem(s) and the body segment. The stem is either an integral part of the reservoir or is joined at some point in the fabrication sequence. The current interest is in high strength stems for advanced reservoir designs. The processing necessary to achieve these strength levels may result in heavily cold worked microstructures which may not interface well with the stem requirements. For instance, cold worked 316 plate stock has shown decreased hydrogen compatibility when contrasted to the annealed version in laboratory tests. More recently, Precision Forge produced a 100 ksi yield strength, 304L stem forging with a heavily deformed microstructure which also may show decreased compatibility in hydrogen. The proposed forging contract will evaluate the influence of forging parameters on the microstructure and mechanical properties of 304L and 316 stem forgings. A summary of the data available on 304L stem forgings is shown graphically. The yield strength values are shown for each set of forging parameters. Tensile tests and microstructural examination will be conducted to complete the information for 304L and create a similar graph for 316 stem forgings.

  5. [Research on the temperature field detection method of large cylinder forgings during heat treatment process based on infrared spectra].

    PubMed

    Zhang, Yu-Cun; Fu, Xian-Bin; Liu, Bin; Qi, Yan-De; Zhou, Shan

    2013-01-01

    In order to grasp the changes of the forging's temperature field during heat treatment, a temperature field detection method based on infrared spectra for large cylinder forgings is proposed in the present paper. On the basis of heat transfer a temperature field model of large barrel forgings was established by the method of separating variables. Using infrared spectroscopy the large forgings temperature measurement system was built based on the three-level interference filter. The temperature field detection of forging was realized in its heat treatment by combining the temperature data and the forgings temperature field detection model. Finally, this method is feasible according to the simulation experiment. The heating forging temperature detection method can provide the theoretical basis for the correct implementation of the heat treatment process. PMID:23586224

  6. FEM Analysis and Experimental Verification of the Integral Forging Process for AP1000 Primary Coolant Pipe

    NASA Astrophysics Data System (ADS)

    Wang, Shenglong; Yu, Xiaoyi; Yang, Bin; Zhang, Mingxian; Wu, Huanchun

    2016-08-01

    AP1000 primary coolant pipes must be manufactured by integral forging technology according to the designer—Westinghouse Electric Co. The characteristics of these large, special-shaped pipes create nonuniform temperatures, effective stress, and effective strain during shaping of the pipes. This paper presents a three-dimensional finite element simulation (3D FEM) of the integral forging process, and qualitatively evaluates the likelihood of forging defects. By analyzing the evolution histories of the three field variables, we concluded that the initial forging temperature should be strictly controlled within the interval 1123 K to 1423 K (850 °C to 1150 °C) to avoid second-phase precipitation. In the hard deformation zones, small strains do not contribute to recrystallization resulting in coarse grains. Conversely, in the free deformation zone, the large strains can contribute to the dynamic recrystallization, favoring grain refinement and closure of voids. Cracks are likely to appear, however, on the workpiece surface when forging leads to large deformations. Based on the simulation results, an eligible workpiece with good mechanical properties, few macroscopic defects, and favorable grain size has been successfully forged by experiments at an industrial scale, which validates the FEM simulation.

  7. Automatic simulation of a sequence of hot-former forging processes by a rigid-thermoviscoplastic finite element method

    SciTech Connect

    Joun, M.S.; Moon, H.K.; Shivpuri, R.

    1998-10-01

    A fully automatic forging simulation technique in hot-former forging is presented in this paper. A rigid-thermoviscoplastic finite element method is employed together with automatic simulation techniques. A realistic analysis model of the hot-former forging processes is given with emphasis on thermal analysis and simulation automation. The whole processes including forming, dwelling, ejecting, and transferring are considered in the analysis model and various cooling conditions are embedded in the analysis model. The approach is applied to a sequence of three-stage hot former forging process. Nonisothermal analysis results are compared with isothermal ones and the effect of heat transfer on predicted metal flows is discussed.

  8. Multi-objective optimization of gear forging process based on adaptive surrogate meta-models

    NASA Astrophysics Data System (ADS)

    Meng, Fanjuan; Labergere, Carl; Lafon, Pascal; Daniel, Laurent

    2013-05-01

    In forging industry, net shape or near net shape forging of gears has been the subject of considerable research effort in the last few decades. So in this paper, a multi-objective optimization methodology of net shape gear forging process design has been discussed. The study is mainly done in four parts: building parametric CAD geometry model, simulating the forging process, fitting surrogate meta-models and optimizing the process by using an advanced algorithm. In order to maximally appropriate meta-models of the real response, an adaptive meta-model based design strategy has been applied. This is a continuous process: first, bui Id a preliminary version of the meta-models after the initial simulated calculations; second, improve the accuracy and update the meta-models by adding some new representative samplings. By using this iterative strategy, the number of the initial sample points for real numerical simulations is greatly decreased and the time for the forged gear design is significantly shortened. Finally, an optimal design for an industrial application of a 27-teeth gear forging process was introduced, which includes three optimization variables and two objective functions. A 3D FE nu merical simulation model is used to realize the process and an advanced thermo-elasto-visco-plastic constitutive equation is considered to represent the material behavior. The meta-model applied for this example is kriging and the optimization algorithm is NSGA-II. At last, a relatively better Pareto optimal front (POF) is gotten with gradually improving the obtained surrogate meta-models.

  9. Hot Forging of a Cladded Component by Automated GMAW Process

    NASA Astrophysics Data System (ADS)

    Rafiq, Muhammad; Langlois, Laurent; Bigot, Régis

    2011-01-01

    Weld cladding is employed to improve the service life of engineering components by increasing corrosion and wear resistance and reducing the cost. The acceptable multi-bead cladding layer depends on single bead geometry. Hence, in first step, the relationship between input process parameters and the single bead geometry is studied and in second step a comprehensive study on multi bead clad layer deposition is carried out. This paper highlights an experimental study carried out to get single layer cladding deposited by automated Gas Metal Arc Welding (GMAW) process and to find the possibility of hot forming of the cladded work piece to get the final hot formed improved structure. GMAW is an arc welding process that uses an arc between a consumable electrode and the welding pool with an external shielding gas and the cladding is done by alongside deposition of weld beads. The experiments for single bead were conducted by varying the three main process parameters wire feed rate, arc voltage and welding speed while keeping other parameters like nozzle to work distance, shielding gas and its flow rate and torch angle constant. The effect of bead spacing and torch orientation on the cladding quality of single layer from the results of single bead deposition was studied. Effect of the dilution rate and nominal energy on the cladded layer hot bending quality was also performed at different temperatures.

  10. Research on the Influence of Technological Forging Parameters on the Quality of Biphasic Titanium Alloys

    NASA Astrophysics Data System (ADS)

    Mashekov, S. A.; Smaylova, N. T.; Alshynova, A. M.; Mashekova, A. S.

    2015-12-01

    The deflected mode (DM) during the preparation of the broach in the flat and combined baizes and also on radial forging machine (RFM) was investigated for creating the rational technology of a broach and determining the optimum size of the angles of rotation and single squeeze reduction. The quantitative data was obtained by the method of final elements and the MSC.Super Forge program; the main consistent patterns of stress-strain state (SSS) distribution and temperature while modeling forging in flat and combined baizes, also on RFM with various angles of rotation and sizes of squeeze reduction were determined. The rational trial technology of forging of biphasic titanium alloys was developed and tested.

  11. Computer-assisted Rheo-forging Processing of A356 Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Kim, H. H.; Kang, C. G.

    2010-06-01

    Die casting process has been used widely for complex automotive products such as the knuckle, arm and etc. Generally, a part fabricated by casting has limited strength due to manufacturing defects by origin such as the dendrite structure and segregation. As an attempt to offer a solution to these problems, forging has been used as an alternative process. However, the forging process provides limited formability for complex shape products. Rheo-forging of metal offers not only superior mechanical strength but also requires significantly lower machine loads than solid forming processes. In order to produce semi-solid materials of the desired microstructure, a stirring process is applied during solidification of A356 aluminum molten state. This paper presents the results of an A356 aluminum alloy sample, which were obtained by experiment and by simulation using DEFORM 3D V6.1. Samples of metal parts were subsequently fabricated by using hydraulic press machinery. In order to compare the influence of loading method, two types of samples were fabricated: (1) samples fabricated under direct loading die sets (2) those fabricated under indirect loading die sets. The formability and defects, which were predicted by FEM simulation, were similar to those of samples used in practice.

  12. Computer-assisted Rheo-forging Processing of A356 Aluminum Alloys

    SciTech Connect

    Kim, H. H.; Kang, C. G.

    2010-06-15

    Die casting process has been used widely for complex automotive products such as the knuckle, arm and etc. Generally, a part fabricated by casting has limited strength due to manufacturing defects by origin such as the dendrite structure and segregation. As an attempt to offer a solution to these problems, forging has been used as an alternative process. However, the forging process provides limited formability for complex shape products. Rheo-forging of metal offers not only superior mechanical strength but also requires significantly lower machine loads than solid forming processes. In order to produce semi-solid materials of the desired microstructure, a stirring process is applied during solidification of A356 aluminum molten state. This paper presents the results of an A356 aluminum alloy sample, which were obtained by experiment and by simulation using DEFORM 3D V6.1. Samples of metal parts were subsequently fabricated by using hydraulic press machinery. In order to compare the influence of loading method, two types of samples were fabricated: (1) samples fabricated under direct loading die sets (2) those fabricated under indirect loading die sets. The formability and defects, which were predicted by FEM simulation, were similar to those of samples used in practice.

  13. Manufacturing of Precision Forgings by Radial Forging

    SciTech Connect

    Wallner, S.; Harrer, O.; Buchmayr, B.; Hofer, F.

    2011-01-17

    Radial forging is a multi purpose incremental forging process using four tools on the same plane. It is widely used for the forming of tool steels, super alloys as well as titanium- and refractory metals. The range of application goes from reducing the diameters of shafts, tubes, stepped shafts and axels, as well as for creating internal profiles for tubes in Near-Net-Shape and Net-Shape quality. Based on actual development of a weight optimized transmission input shaft, the specific features of radial forging technology is demonstrated. Also a Finite Element Model for the simulation of the process is shown which leads to reduced pre-processing effort and reduced computing time compared to other published simulation methods for radial forging. The finite element model can be applied to quantify the effects of different forging strategies.

  14. Experimental and Numerical Investigation of Forging Process to Reproduce a 3D Aluminium Foam Complex Shape

    SciTech Connect

    Filice, Luigino; Gagliardi, Francesco; Umbrello, Domenico; Shivpuri, Rajiv

    2007-05-17

    Metallic foams represent one of the most exciting materials introduced in the manufacturing scenario in the last years. In the study here addressed, the experimental and numerical investigations on the forging process of a simple foam billet shaped into complex sculptured parts were carried out. In particular, the deformation behavior of metallic foams and the development of density gradients were investigated through a series of experimental forging tests in order to produce a selected portion of a hip prosthesis. The human bone replacement was chosen as case study due to its industrial demand and for its particular 3D complex shape. A finite element code (Deform 3D) was utilized for modeling the foam behavior during the forging process and an accurate material rheology description was used based on a porous material model which includes the measured local density. Once the effectiveness of the utilized Finite Element model was verified through the comparison with the experimental evidences, a numerical study of the influence of the foam density was investigated. The obtained numerical results shown as the initial billet density plays an important role on the prediction of the final shape, the optimization of the flash as well as the estimation of the punch load.

  15. Experimental and Numerical Investigation of Forging Process to Reproduce a 3D Aluminium Foam Complex Shape

    NASA Astrophysics Data System (ADS)

    Filice, Luigino; Gagliardi, Francesco; Shivpuri, Rajiv; Umbrello, Domenico

    2007-05-01

    Metallic foams represent one of the most exciting materials introduced in the manufacturing scenario in the last years. In the study here addressed, the experimental and numerical investigations on the forging process of a simple foam billet shaped into complex sculptured parts were carried out. In particular, the deformation behavior of metallic foams and the development of density gradients were investigated through a series of experimental forging tests in order to produce a selected portion of a hip prosthesis. The human bone replacement was chosen as case study due to its industrial demand and for its particular 3D complex shape. A finite element code (Deform 3D®) was utilized for modeling the foam behavior during the forging process and an accurate material rheology description was used based on a porous material model which includes the measured local density. Once the effectiveness of the utilized Finite Element model was verified through the comparison with the experimental evidences, a numerical study of the influence of the foam density was investigated. The obtained numerical results shown as the initial billet density plays an important role on the prediction of the final shape, the optimization of the flash as well as the estimation of the punch load.

  16. Simulations and Experiments of the Nonisothermal Forging Process of a Ti-6Al-4V Impeller

    NASA Astrophysics Data System (ADS)

    Prabhu, T. Ram

    2016-06-01

    In the present study, a nonisothermal precision forging process of a Ti-6Al-4V first-stage impeller for the gas turbine engine was simulated using the finite element software. The simulation results such as load requirements, damage, velocity field, stress, strain, and temperature distributions are discussed in detail. Simulations predicted the maximum load requirement of about 80 MN. The maximum temperature loss was observed at the contour surface regions. The center and contour regions are the high-strained regions in the part. To validate the model, forging experiments mimicking simulations were performed in the α + β phases region (930 °C). The selected locations of the part were characterized for tensile properties at 27 and 200 °C, hardness, microstructure, grain size, and the amount of primary α phase based on the strain distribution results. The soundness of the forged part was verified using fluorescent penetrant test (Mil Std 2175 Grade A) and ultrasonic test (AMS 2630 class A1). From the experimental results, it was found that the variations in the hardness, tensile properties at room, and elevated temperature are not significant. The microstructure, grain size, and primary α phase content are nearly same.

  17. Changes in magnetic parameters of neutron irradiated SA 508 Cl. 3 reactor pressure vessel forging and weld surveillance specimens

    NASA Astrophysics Data System (ADS)

    Chi, Se-Hwan; Chang, Kee-Ok; Hong, Jun-Hwa; Kuk, Il-Hiun; Kim, Chong-Oh

    1999-04-01

    Irradiation-induced changes in the magnetic parameters and mechanical properties were measured and compared to explore possible correlations for reactor pressure vessel (RPV) forging and weld surveillance Charpy specimens which were irradiated to the neutron fluence of 2.3×1019n/cm2 (E>1.0 MeV) in a typical pressurized water reactor environment at 290 °C. For mechanical property parameters, Vickers microhardness, tensile and Charpy impact tests were performed and saturation magnetization (Ms), remanence (Mr), coercivity (Hc), and Barkhausen noise amplitude (BNA) were measured for magnetic parameters for both unirradiated and irradiated specimens, respectively. Results of mechanical property measurements showed an increase in yield and tensile strength, Vickers microhardness, 30 ft. lb indexed RTNDT and a decrease in Charpy upper-shelf energy irrespective of forging and weld metals. Hysteresis loops appeared to turn clockwise, resulting in an increase in Hc, and BNA appeared to decrease after irradiation. Both magnetic parameters showed viable correlations to the changes in mechanical parameters (Vickers microhardness, Charpy upper shelf energy) due to irradiation. Even limited, the present study seems to show additional possibilities for the application of this magnetic method in monitoring the mechanical parameter changes due to neutron irradiation.

  18. Development of Replacements for Phoscoating Used in Forging, Extrusion and Metal Forming Processes

    SciTech Connect

    Kerry Barnett

    2003-03-01

    Many forging, extrusion, heading and other metal forming processes use graphite-based lubricants, phosphate coatings, and other potentially hazardous or harmful substances to improve the tribology of the metal forming process. The application of phosphate-based coatings has long been studied to determine if other synthetic ''clean'' lubricants could provide the same degree of protection afforded by phoscoatings and its formulations. So far, none meets the cost and performance objectives provided by phoscoatings as a general aid to the metal forming industry. In as much as phoscoatings and graphite have replaced lead-based lubricants, the metal forming industry has had previous experience with a legislated requirement to change processes. However, without a proactive approach to phoscoating replacement, many metal forming processes could find themselves without a cost effective tribology material necessary for the metal forming process

  19. Correcting the Stress-Strain Curve in the Stroke-Rate Controlling Forging Process

    NASA Astrophysics Data System (ADS)

    Li, Y. P.; Matsumoto, H.; Chiba, A.

    2009-05-01

    In this article, a detailed description of the friction correction, adiabatic correction, and the correction from the stroke-rate controlling process into the strain-rate controlling process on the IHS38MSV hypoeutectoid steel is provided. By using compensated data, processing maps were plotted and used to predict the optimum hot forging process. The compressive tests were performed at stroke rates ranging from 0.12 to 120 mm/s and temperatures ranging from 800 °C to 1200 °C by using ThermecMaster-Z equipment. The results showed that the correction by instant friction coefficient, which was carried out on the basis of previous research, could be extended to wider experimental conditions. The corrected data from both stroke-rate controlling and strain-rate controlling processes were in good agreement with each other, indicating that the present correction from the stroke rate into the strain-rate correction is practical and appropriate.

  20. Liquid State Forging: Novel Potentiality to Produce High Performance Components, Process, Plant and Tooling

    NASA Astrophysics Data System (ADS)

    Rosso, M.; Zago, A.; Claus, P.; Motoiu, P.

    2007-04-01

    The paper deals about a new patented process able to the production of high resistance and high toughness parts, taking into consideration also the tooling need. The molten alloy is introduced into the die cavity at low pressure, then the alloy is forged. The forging action takes place during the alloy solidification process, favouring the reduction of the duration of the process and the production of parts characterised by very high mechanical and ductility properties. The very high mechanical characteristics of the produced parts are obtained thank to their very low porosity content, as well as to their unique microstructure features. Moreover, the process allow the optimisation of the yield of the alloy, in fact the feeding system and the risers are practically absent, this means minimum production of scraps to be recycled. After a short description of the main features of the equipment and of the process, the work take into consideration the aluminium based produced parts, in their as cast state and after T6 heat treatment, comparing their characteristics with those obtainable by the most traditional low pressure and gravity casting processes. In particular, samples for the evaluation of the mechanical properties have been machined from the produced parts to obtain their tensile strength, together with their ductility characteristics. The maximum attained hardness values have also been evaluated. Tensile strength higher than 440 MPa, with elongation up to 18% with hardness higher than 125 HB are easily attainable on Al alloys type A356. Light microscopy observations performed on the transverse section of polished samples and the analysis of the fracture surfaces after mechanical tests allowed to focus the attention on the microstructure details and to highlight the ductile aspects of the fracture to confirm the high quality and high performance of the produced parts.

  1. Modeling of Closed-Die Forging for Estimating Forging Load

    NASA Astrophysics Data System (ADS)

    Sheth, Debashish; Das, Santanu; Chatterjee, Avik; Bhattacharya, Anirban

    2016-05-01

    Closed die forging is one common metal forming process used for making a range of products. Enough load is to exert on the billet for deforming the material. This forging load is dependent on work material property and frictional characteristics of the work material with the punch and die. Several researchers worked on estimation of forging load for specific products under different process variables. Experimental data on deformation resistance and friction were used to calculate the load. In this work, theoretical estimation of forging load is made to compare this value with that obtained through LS-DYNA model facilitating the finite element analysis. Theoretical work uses slab method to assess forging load for an axi-symmetric upsetting job made of lead. Theoretical forging load estimate shows slightly higher value than the experimental one; however, simulation shows quite close matching with experimental forging load, indicating possibility of wide use of this simulation software.

  2. Forging; Heat Treating and Testing; Technically Oriented Industrial Materials and Process 1: 5898.05.

    ERIC Educational Resources Information Center

    Dade County Public Schools, Miami, FL.

    The course provides students with advanced and exploratory experience in the area of plastic deformation of metals and in the changing of the physical characteristics of metals by the controlled application and timed removal of heat. Course content includes goals, specific objectives, safety in forge work, forging tools and equipment, industrial…

  3. Process Damping Parameters

    NASA Astrophysics Data System (ADS)

    Turner, Sam

    2011-12-01

    The phenomenon of process damping as a stabilising effect in milling has been encountered by machinists since milling and turning began. It is of great importance when milling aerospace alloys where maximum surface speed is limited by excessive tool wear and high speed stability lobes cannot be attained. Much of the established research into regenerative chatter and chatter avoidance has focussed on stability lobe theory with different analytical and time domain models developed to expand on the theory first developed by Trusty and Tobias. Process damping is a stabilising effect that occurs when the surface speed is low relative to the dominant natural frequency of the system and has been less successfully modelled and understood. Process damping is believed to be influenced by the interference of the relief face of the cutting tool with the waveform traced on the cut surface, with material properties and the relief geometry of the tool believed to be key factors governing performance. This study combines experimental trials with Finite Element (FE) simulation in an attempt to identify and understand the key factors influencing process damping performance in titanium milling. Rake angle, relief angle and chip thickness are the variables considered experimentally with the FE study looking at average radial and tangential forces and surface compressive stress. For the experimental study a technique is developed to identify the critical process damping wavelength as a means of measuring process damping performance. For the range of parameters studied, chip thickness is found to be the dominant factor with maximum stable parameters increased by a factor of 17 in the best case. Within the range studied, relief angle was found to have a lesser effect than expected whilst rake angle had an influence.

  4. Processing and properties of superclean ASTM A508 Cl. 4 forgings

    SciTech Connect

    Hinkel, A.V.; Handerhan, K.J.; Manzo, G.J.; Simkins, G.P.

    1988-12-31

    Steels with improved resistance to temper embrittlement are now being produced using ``superclean`` steelmaking technology. This technology involves the use of scrap control, proper electric arc furnace and ladle refining furnace practices to produce steel with very low Mn, Si, P, S and other residual impurities such as Sn, As and Sb. This technology has been applied on a production basis to modified ASTM A508 Cl- 4 material intended for high temperature pressure vessel forgings. Processing and properties of this superclean material are reviewed. In addition, the cleanliness and mechanical properties are compared to conventionally melted A508 Cl. 4 material. The ``superclean`` A508 Cl. 4 mod. was found to meet all specification requirements. In addition, the superclean material was found to possess superior upper shelf CVN properties, a lower FATT{sub 50} and NDTT, along with superior microcleanliness compared to conventional material. Finally, the superclean material was found to be immune to temper embrittlement based on the short-term embrittlement treatments examined.

  5. Effect of forging parameters on low cycle fatigue behaviour of Al/basalt short fiber metal matrix composites.

    PubMed

    Karthigeyan, R; Ranganath, G

    2013-01-01

    This paper deals with metal matrix composites (MMCs) of Al 7075 alloy containing different weight percentage (2.5, 5, 7.5, and 10) basalt short fiber reinforcement and unreinforced matrix alloy. The samples were produced by the permanent stir casting technique. The casting ingots were cut into blanks to be forged in single stage and double stage, using MN press and graphite-based lubricant. The microstructures and fatigue properties of the matrix alloy and MMC samples were investigated in the as cast state and in the single and double stage forging operations. The microstructure results showed that the forged sample had a uniform distribution of the basalt short fiber throughout the specimens. Evaluation of the fatigue properties showed that the forged samples had higher values than those of the as cast counterparts. After forging, the enhancement of the fatigue strength of the matrix alloy was so significant and high in the case of 2.5 and 5.0 wt. percentage basalt short fiber reinforced MMC, and there was no enhancement in 7.5 and 10 weight percentages short fiber reinforced MMCs. The fracture damage was mainly due to decohesion at the matrix-fiber interface. PMID:24298207

  6. Effect of Forging Parameters on Low Cycle Fatigue Behaviour of Al/Basalt Short Fiber Metal Matrix Composites

    PubMed Central

    Karthigeyan, R.; Ranganath, G.

    2013-01-01

    This paper deals with metal matrix composites (MMCs) of Al 7075 alloy containing different weight percentage (2.5, 5, 7.5, and 10) basalt short fiber reinforcement and unreinforced matrix alloy. The samples were produced by the permanent stir casting technique. The casting ingots were cut into blanks to be forged in single stage and double stage, using MN press and graphite-based lubricant. The microstructures and fatigue properties of the matrix alloy and MMC samples were investigated in the as cast state and in the single and double stage forging operations. The microstructure results showed that the forged sample had a uniform distribution of the basalt short fiber throughout the specimens. Evaluation of the fatigue properties showed that the forged samples had higher values than those of the as cast counterparts. After forging, the enhancement of the fatigue strength of the matrix alloy was so significant and high in the case of 2.5 and 5.0 wt. percentage basalt short fiber reinforced MMC, and there was no enhancement in 7.5 and 10 weight percentages short fiber reinforced MMCs. The fracture damage was mainly due to decohesion at the matrix-fiber interface. PMID:24298207

  7. Formation and Microstructure of Ultrafine-Grained Titanium Processed by Multi-Directional Forging

    NASA Astrophysics Data System (ADS)

    Wang, Bingfeng; Wang, Xiaoyan; Li, Juan

    2016-06-01

    Ultrafine-grained titanium with uniform grain size for medical applications is obtained by multi-directional forging at 773 K in air. The microstructures and microtextures in the deformed titanium specimens are investigated by optical microscopy, electron backscattered diffraction technique, and transmission electron microscopy. Titanium specimen experience the recrystallization softening at cumulative strain about 1.2. After six passes with the cumulative strains of 2.4, the coarse grain sizes are gradually refined from about 25 μm to about 0.2 μm. New microtextures with recrystallized features generate in the specimens after multi-directional forgings. Grain boundaries in the specimens are geometrical necessary boundaries aiming to accommodate the imposed strain. It is suggested that the continuous dynamic recrystallization induced by deformation bands is responsible for the formation of ultrafine-grained titanium during multi-directional forging. Meanwhile the subdivision of grains by the mechanical twinning dramatically enhanced grain refinement to develop ultrafine-grained microstructure.

  8. Formation and Microstructure of Ultrafine-Grained Titanium Processed by Multi-Directional Forging

    NASA Astrophysics Data System (ADS)

    Wang, Bingfeng; Wang, Xiaoyan; Li, Juan

    2016-05-01

    Ultrafine-grained titanium with uniform grain size for medical applications is obtained by multi-directional forging at 773 K in air. The microstructures and microtextures in the deformed titanium specimens are investigated by optical microscopy, electron backscattered diffraction technique, and transmission electron microscopy. Titanium specimen experience the recrystallization softening at cumulative strain about 1.2. After six passes with the cumulative strains of 2.4, the coarse grain sizes are gradually refined from about 25 μm to about 0.2 μm. New microtextures with recrystallized features generate in the specimens after multi-directional forgings. Grain boundaries in the specimens are geometrical necessary boundaries aiming to accommodate the imposed strain. It is suggested that the continuous dynamic recrystallization induced by deformation bands is responsible for the formation of ultrafine-grained titanium during multi-directional forging. Meanwhile the subdivision of grains by the mechanical twinning dramatically enhanced grain refinement to develop ultrafine-grained microstructure.

  9. Bioresorbable composite screws manufactured via forging process: pull-out, shear, flexural and degradation characteristics.

    PubMed

    Felfel, R M; Ahmed, I; Parsons, A J; Rudd, C D

    2013-02-01

    Bioresorbable screws have the potential to overcome some of the complications associated with metallic screws currently in use. Removal of metallic screws after bone has healed is a serious issue which can lead to refracture due to the presence of screw holes. Poly lactic acid (PLA), fully 40 mol% P(2)O(5) containing phosphate unidirectional (P40UD) and a mixture of UD and short chopped strand random fibre mats (P40 70%UD/30%RM) composite screws were prepared via forging composite bars. Water uptake and mass loss for the composite screws manufactured increased significantly to ∼1.25% (P=0.0002) and ∼1.1% (P<0.0001), respectively, after 42 days of immersion in PBS at 37 °C. The initial maximum flexural load for P40 UD/RM and P40 UD composite screws was ∼60% (P=0.0047) and ∼100% (P=0.0037) higher than for the PLA screws (∼190 N), whilst the shear load was slightly higher in comparison to PLA (∼2.2 kN). The initial pull-out strengths for the P40 UD/RM and PLA screws were similar whereas that for P40 UD screws was ∼75% higher (P=0.022). Mechanical properties for the composite screws decreased initially after 3 days of immersion and this reduction was ascribed to the degradation of the fibre/matrix interface. After 3 days interval the mechanical properties (flexural, shear and pull-out) maintained their integrity for the duration of the study (at 42 days). This property retention was attributed to the chemical durability of the fibres used and stability of the matrix properties during the degradation process. It was also deemed necessary to enhance the fibre/matrix interface via use of a coupling agent in order to maintain the initial mechanical properties acquired for the required period of time. Lastly, it is also suggested that the degrading reinforcement fibres may have the potential to buffer any acidic products released from the PLA matrix. PMID:23262309

  10. Process Modeling In Cold Forging Considering The Process-Tool-Machine Interactions

    NASA Astrophysics Data System (ADS)

    Kroiss, Thomas; Engel, Ulf; Merklein, Marion

    2010-06-01

    In this paper, a methodic approach is presented for the determination and modeling of the axial deflection characteristic for the whole system of stroke-controlled press and tooling system. This is realized by a combination of experiment and FE simulation. The press characteristic is uniquely measured in experiment. The tooling system characteristic is determined in FE simulation to avoid experimental investigations on various tooling systems. The stiffnesses of press and tooling system are combined to a substitute stiffness that is integrated into the FE process simulation as a spring element. Non-linear initial effects of the press are modeled with a constant shift factor. The approach was applied to a full forward extrusion process on a press with C-frame. A comparison between experiments and results of the integrated FE simulation model showed a high accuracy of the FE model. The simulation model with integrated deflection characteristic represents the entire process behavior and can be used for the calculation of a mathematical process model based on variant simulations and response surfaces. In a subsequent optimization step, an adjusted process and tool design can be determined, that compensates the influence of the deflections on the workpiece dimensions leading to high workpiece accuracy. Using knowledge on the process behavior, the required number of variant simulations was reduced.

  11. New Trends in Forging Technologies

    NASA Astrophysics Data System (ADS)

    Behrens, B.-A.; Hagen, T.; Knigge, J.; Elgaly, I.; Hadifi, T.; Bouguecha, A.

    2011-05-01

    Limited natural resources increase the demand on highly efficient machinery and transportation means. New energy-saving mobility concepts call for design optimisation through downsizing of components and choice of corrosion resistant materials possessing high strength to density ratios. Component downsizing can be performed either by constructive structural optimisation or by substituting heavy materials with lighter high-strength ones. In this context, forging plays an important role in manufacturing load-optimised structural components. At the Institute of Metal Forming and Metal-Forming Machines (IFUM) various innovative forging technologies have been developed. With regard to structural optimisation, different strategies for localised reinforcement of components were investigated. Locally induced strain hardening by means of cold forging under a superimposed hydrostatic pressure could be realised. In addition, controlled martensitic zones could be created through forming induced phase conversion in metastable austenitic steels. Other research focused on the replacement of heavy steel parts with high-strength nonferrous alloys or hybrid material compounds. Several forging processes of magnesium, aluminium and titanium alloys for different aeronautical and automotive applications were developed. The whole process chain from material characterisation via simulation-based process design to the production of the parts has been considered. The feasibility of forging complex shaped geometries using these alloys was confirmed. In spite of the difficulties encountered due to machine noise and high temperature, acoustic emission (AE) technique has been successfully applied for online monitoring of forging defects. New AE analysis algorithm has been developed, so that different signal patterns due to various events such as product/die cracking or die wear could be detected and classified. Further, the feasibility of the mentioned forging technologies was proven by means

  12. Examination on the use of acoustic emission for monitoring metal forging process: A study using simulation technique

    SciTech Connect

    Mullins, W.M.; Malas, J.C. III; Venugopal, S.

    1997-05-01

    The aim of this study is to determine the feasibility of using acoustic emission as a monitoring technique for metal forging operations. From the sensor development paradigm proposed by McClean et al. the most likely approach to determining feasibility for application is through signal recognition. For this reason, signature prediction and analysis was chosen to determine the suitability for forging applications.

  13. High-energy rate forgings of wedges :

    SciTech Connect

    Reynolds, Thomas Bither; Everhart, Wesley; Switzner, Nathan T; Balch, Dorian K.; San Marchi, Christopher W.

    2014-05-01

    The wedge geometry is a simple geometry for establishing a relatively constant gradient of strain in a forged part. The geometry is used to establish gradients in microstructure and strength as a function of strain, forging temperature, and quenching time after forging. This geometry has previously been used to benchmark predictions of strength and recrystallization using Sandias materials model for type 304L austenitic stainless steel. In this report, the processing conditions, in particular the times to forge and quench the forged parts, are summarized based on information recorded during forging on June 18, 2013 of the so-called wedge geometry from type 316L and 21Cr-6Ni-9Mn austenitic stainless steels.

  14. Forgings meet the challenges of the future

    SciTech Connect

    Mochnal, G.

    1996-04-01

    To meet and exceed the requirements of the customer of the future, the forging industry is entering a new era of increased productivity and technical advancements. The tools for this task have been developed as a result of a partnership among industry, government, and academia. As another consequence of this partnership, the Forging Industry Association and the Forging Industry Educational and Research Foundation are in the process of creating a Vision of the Future. This article will discuss advances in metal-forming simulation, billet heating systems, advanced die materials, and advanced forging presses.

  15. Forging processes: Lubrication. January 1970-January 1990 (A Bibliography from the COMPENDEX data base). Report for January 1970-January 1990

    SciTech Connect

    Not Available

    1990-05-01

    This bibliography contains citations concerning lubricants used in the forging industries to reduce tool wear and help prevent buildup formation on tools. Methods developed to select and evaluate forging lubricants for both safety and effectiveness are described. Low-pollution level, water-based synthetic lubricants, and non-corrosive, graphite-free lubricants are described. Mathematical modelling and finite element analyses used to determine lubricant dosage and distribution are included. (Contains 189 citations fully indexed and including a title list.)

  16. Forging of Advanced Disk Alloy LSHR

    NASA Technical Reports Server (NTRS)

    Gabb, Timothy P.; Gayda, John; Falsey, John

    2005-01-01

    The powder metallurgy disk alloy LSHR was designed with a relatively low gamma precipitate solvus temperature and high refractory element content to allow versatile heat treatment processing combined with high tensile, creep and fatigue properties. Grain size can be chiefly controlled through proper selection of solution heat treatment temperatures relative to the gamma precipitate solvus temperature. However, forging process conditions can also significantly influence solution heat treatment-grain size response. Therefore, it is necessary to understand the relationships between forging process conditions and the eventual grain size of solution heat treated material. A series of forging experiments were performed with subsequent subsolvus and supersolvus heat treatments, in search of suitable forging conditions for producing uniform fine grain and coarse grain microstructures. Subsolvus, supersolvus, and combined subsolvus plus supersolvus heat treatments were then applied. Forging and subsequent heat treatment conditions were identified allowing uniform fine and coarse grain microstructures.

  17. Numerical Simulation on the Die Filling Process of the Thixo-Forging of Al-7 wt pct Si/Al-22 wt pct Si Bimetal Composite

    NASA Astrophysics Data System (ADS)

    Wang, Guangxu; Huang, Honghua; Yang, Zhao; Shi, Xiaocheng; He, Xiaolong

    2015-10-01

    A bimetal semi-solid fluid has more complicated flow behaviors than a normal semi-solid fluid during thixo-forging. In order to clarify the detailed properties of the bimetal thixo-forging, the effects of billet temperatures and frictions on flow behaviors of the Al-7 wt pct Si/Al-22 wt pct Si bimetal thixo-forging were investigated by commercial software DEFORM-3D. The simulation results show that shear force was unable to be transferred from the upper billet on the drop die side to the bottom billet on the counter die side efficiently in the initial stage of die filling. Only when the upper billet severely deformed, did the shear force deform the bottom billet. A stiffer upper billet can enhance the efficiency of shear force transfer. The processing temperature, the relative stiffness between the upper billet and bottom billet, and frictions between dies and billets, as well as friction between billets, were important factors to control the interface outline of the bimetal parts. The experimental results are consistent with the simulation results.

  18. Effect of Various Heat Treatment Processes on Fatigue Behavior of Tool Steel for Cold Forging Die

    NASA Astrophysics Data System (ADS)

    Jin, S. U.; Kim, S. S.; Lee, Y. S.; Kwon, Y. N.; Lee, J. H.

    Effects of various heat treatment processes, including "Q/T (quenching and tempering)", "Q/CT/T (Quenching, cryogenic treatment and tempering)", "Q/T (quenching and tempering) + Ti-nitriding" and "Q/CT/T (Cryogenic treatment and tempering) + Ti-nitriding", on S-N fatigue behavior of AISI D2 tool steel were investigated. The optical micrographs and Vicker's hardness values at near surface and core area were examined for each specimen. Uniaxial fatigue tests were performed by using an electro-magnetic resonance fatigue testing machine at a frequency of 80 Hz and an R ratio of -1. The overall resistance to fatigue tends to decrease significantly with Ti-nitriding treatment compared to those for the general Q/T and Q/CT/T specimens. The reduced resistance to fatigue with Ti-nitriding is discussed based on the microstructural and fractographic analyses.

  19. Simulation of 7050 Wrought Aluminum Alloy Wheel Die Forging and its Defects Analysis based on DEFORM

    SciTech Connect

    Huang Shiquan; Yi Youping; Zhang Yuxun

    2010-06-15

    Defects such as folding, intercrystalline cracking and flow lines outcrop are very likely to occur in the forging of aluminum alloy. Moreover, it is difficult to achieve the optimal set of process parameters just by trial and error within an industrial environment. In producing 7050 wrought aluminum alloy wheel, a rigid-plastic finite element method (FEM) analysis has been performed to optimize die forging process. Processing parameters were analyzed, focusing on the effects of punch speed, friction factor and temperature. Meanwhile, mechanism as well as the evolution with respect to the defects of the wrought wheel was studied in details. From an analysis of the results, isothermal die forging was proposed for producing 7050 aluminum alloy wheel with good mechanical properties. Finally, verification experiment was carried out on hydropress.

  20. Phased Array Ultrasonic Inspection of Titanium Forgings

    SciTech Connect

    Howard, P.; Klaassen, R.; Kurkcu, N.; Barshinger, J.; Chalek, C.; Nieters, E.; Sun, Zongqi; Fromont, F. de

    2007-03-21

    Aerospace forging inspections typically use multiple, subsurface-focused sound beams in combination with digital C-scan image acquisition and display. Traditionally, forging inspections have been implemented using multiple single element, fixed focused transducers. Recent advances in phased array technology have made it possible to perform an equivalent inspection using a single phased array transducer. General Electric has developed a system to perform titanium forging inspection based on medical phased array technology and advanced image processing techniques. The components of that system and system performance for titanium inspection will be discussed.

  1. Superplastic forging nitride ceramics

    DOEpatents

    Panda, P.C.; Seydel, E.R.; Raj, R.

    1988-03-22

    A process is disclosed for preparing silicon nitride ceramic parts which are relatively flaw free and which need little or no machining, said process comprising the steps of: (a) preparing a starting powder by wet or dry mixing ingredients comprising by weight from about 70% to about 99% silicon nitride, from about 1% to about 30% of liquid phase forming additive and from 1% to about 7% free silicon; (b) cold pressing to obtain a preform of green density ranging from about 30% to about 75% of theoretical density; (c) sintering at atmospheric pressure in a nitrogen atmosphere at a temperature ranging from about 1,400 C to about 2,200 C to obtain a density which ranges from about 50% to about 100% of theoretical density and which is higher than said preform green density, and (d) press forging workpiece resulting from step (c) by isothermally uniaxially pressing said workpiece in an open die without initial contact between said workpiece and die wall perpendicular to the direction of pressing and so that pressed workpiece does not contact die wall perpendicular to the direction of pressing, to substantially final shape in a nitrogen atmosphere utilizing a temperature within the range of from about 1,400 C to essentially 1,750 C and strain rate within the range of about 10[sup [minus]7] to about 10[sup [minus]1] seconds[sup [minus]1], the temperature and strain rate being such that surface cracks do not occur, said pressing being carried out to obtain a shear deformation greater than 30% whereby superplastic forging is effected.

  2. Controlled Forging of a Nb Containing Microalloyed Steel for Automotive Applications

    NASA Astrophysics Data System (ADS)

    Nakhaie, Davood; Hosseini Benhangi, Pooya; Fazeli, Fateh; Mazinani, Mohammad; Zohourvahid Karimi, Ebrahim; Ghandehari Ferdowsi, Mahmoud Reza

    2012-12-01

    Controlled forging of microalloyed steels is a viable economical process for the manufacture of automotive parts. Ferrite grain refinement and precipitation hardening are the major microstructural parameters to enhance the mechanical properties of the forged components. In the current study, a modified thermomechanical treatment for additional ferrite grain refinement is developed by exploiting the effect of Nb in increasing the T NR (no recrystallization temperature) and via phase transformation from a pancaked austenite. This is accomplished by performing the final passes of forging below the T NR temperature followed by a controlled cooling stage to produce a mixture of fine grained ferrite, small scaled acicular ferrite as well as a limited amount of martensite. The effect of processing parameters in terms of forging strain, cooling rate and aging condition on the microstructure and mechanical properties of a medium carbon, Nb containing microalloyed steel is investigated. An attempt is made to identify a suitable microstructure that provides a proper combination of high strength and good impact toughness. The processing-microstructure relationships for the proposed novel forging procedure are discussed, and directions for further improvements are outlined.

  3. Effect of Process Parameters on Microstructure and Hardness of Oxide Dispersion Strengthened 18Cr Ferritic Steel

    NASA Astrophysics Data System (ADS)

    Nagini, M.; Vijay, R.; Rajulapati, Koteswararao V.; Rao, K. Bhanu Sankara; Ramakrishna, M.; Reddy, A. V.; Sundararajan, G.

    2016-08-01

    Pre-alloyed ferritic 18Cr steel (Fe-18Cr-2.3W-0.3Ti) powder was milled with and without nano-yttria in high-energy ball mill for varying times until steady-state is reached. The milled powders were consolidated by upset forging followed by hot extrusion. Microstructural changes were examined at all stages of processing (milling, upset forging, and extrusion). In milled powders, crystallite size decreases and hardness increases with increasing milling time reaching a steady-state beyond 5 hours. The size of Y2O3 particles in powders decreases with milling time and under steady-state milling conditions; the particles either dissolve in matrix or form atomic clusters. Upset forged sample consists of unrecrystallized grain structure with few pockets of fine recrystallized grains and dispersoids of 2 to 4 nm. In extruded and annealed rods, the particles are of cuboidal Y2Ti2O7 at all sizes and their size decreased from 15 nm to 5 nm along with significant increase in number density. The oxide particles in ODS6 are of cuboidal Y2Ti2O7 with diamond cubic crystal structure ( Fd bar{3} m) having a lattice parameter of 10.1 Å and are semicoherent with the matrix. The hardness values of extruded and annealed samples predicted by linear summation model compare well with measured values.

  4. Effect of Process Parameters on Microstructure and Hardness of Oxide Dispersion Strengthened 18Cr Ferritic Steel

    NASA Astrophysics Data System (ADS)

    Nagini, M.; Vijay, R.; Rajulapati, Koteswararao V.; Rao, K. Bhanu Sankara; Ramakrishna, M.; Reddy, A. V.; Sundararajan, G.

    2016-06-01

    Pre-alloyed ferritic 18Cr steel (Fe-18Cr-2.3W-0.3Ti) powder was milled with and without nano-yttria in high-energy ball mill for varying times until steady-state is reached. The milled powders were consolidated by upset forging followed by hot extrusion. Microstructural changes were examined at all stages of processing (milling, upset forging, and extrusion). In milled powders, crystallite size decreases and hardness increases with increasing milling time reaching a steady-state beyond 5 hours. The size of Y2O3 particles in powders decreases with milling time and under steady-state milling conditions; the particles either dissolve in matrix or form atomic clusters. Upset forged sample consists of unrecrystallized grain structure with few pockets of fine recrystallized grains and dispersoids of 2 to 4 nm. In extruded and annealed rods, the particles are of cuboidal Y2Ti2O7 at all sizes and their size decreased from 15 nm to 5 nm along with significant increase in number density. The oxide particles in ODS6 are of cuboidal Y2Ti2O7 with diamond cubic crystal structure (Fd bar{3} m) having a lattice parameter of 10.1 Å and are semicoherent with the matrix. The hardness values of extruded and annealed samples predicted by linear summation model compare well with measured values.

  5. Enhancement of Aluminum Alloy Forgings through Rapid Billet Heating

    SciTech Connect

    Kervick, R.; Blue, C. A.; Kadolkar, P. B.; Ando, T.; Lu, H.; Nakazawa, K.; Mayer, H.; Mochnal, G.

    2006-06-01

    Forging is a manufacturing process in which metal is pressed, pounded or squeezed under great pressure and, often, under high strain rates into high-strength parts known as forgings. The process is typically performed hot by preheating the metal to a desired temperature before it is worked. The forging process can create parts that are stronger than those manufactured by any other metal working process. Forgings are almost always used where reliability and human safety are critical. Forgings are normally component parts contained inside assembled items such airplanes, automobiles, tractors, ships, oil drilling equipment, engines missiles, and all kinds of capital equipment Forgings are stronger than castings and surpass them in predictable strength properties, producing superior strength that is assured, part to part.

  6. Estimation of friction under forging conditions by means of the ring-on-disc test

    SciTech Connect

    Buchner, Bernhard; Umgeher, Andreas; Buchmayr, Bruno

    2007-04-07

    In order to understand the tribological processes and interactions in the tool-workpiece-interface systematically, basic experiments that allow an independent variation of influencing parameters are necessary. The ring-on-disc test is a popular model experiment that is often used in tribological analyses at low normal contact pressures.The scope of the paper is an analysis of the applicability of the ring-on-disc test for high normal pressures as used in forging processes, using aluminium AA6082 as workpiece material. It turned out, that this test is a convenient method to measure friction under forging conditions.

  7. Mechanical Testing Development for Reservoir Forgings

    SciTech Connect

    Wenski, E.G.

    2000-05-22

    The goal of this project was to determine the machining techniques and testing capabilities required for mechanical property evaluation of commercially procured reservoir forgings. Due to the small size of these specific forgings, specialized methods are required to adequately machine and test these sub-miniature samples in accordance with the requirements of ASTM-E8 and ASTM-E9. At the time of project initiation, no capability existed at Federal Manufacturing & Technologies (FM&T) to verify the physical properties of these reservoirs as required on the drawing specifications. The project determined the sample definitions, machining processes, and testing procedures to verify the physical properties of the reservoir forgings; specifically, tensile strength, yield strength, reduction of area, and elongation. In addition, a compression test method was also developed to minimize sample preparation time and provide a more easily machined test sample while maintaining the physical validation of the forging.

  8. Forging of FeAl intermetallic compounds

    SciTech Connect

    Flores, O.; Juarez, J.; Campillo, B.; Martinez, L.; Schneibel, J.H.

    1994-09-01

    Much activity has been concentrated on the development of intermetallic compounds with the aim of improving tensile ductility, fracture toughness and high notch sensitivity in order to develop an attractive combination of properties for high and low temperature applications. This paper reports experience in processing and forging of FeAl intermetallic of B2 type. During the experiments two different temperatures were employed, and the specimens were forged after annealing in air, 10{sup {minus}2} torr vacuum and argon. From the results it was learned that annealing FeAl in argon atmosphere prior to forging resulted in better deformation behavior than for the other two environments. For the higher forging temperature used in the experiments (700C), the as-cast microstructure becomes partially recrystallized.

  9. Forging Long Shafts On Disks

    NASA Technical Reports Server (NTRS)

    Tilghman, Chris; Askey, William; Hopkins, Steven

    1989-01-01

    Isothermal-forging apparatus produces long shafts integral with disks. Equipment based on modification of conventional isothermal-forging equipment, required stroke cut by more than half. Enables forging of shafts as long as 48 in. (122 cm) on typical modified conventional forging press, otherwise limited to making shafts no longer than 18 in. (46cm). Removable punch, in which forged material cools after plastic deformation, essential novel feature of forging apparatus. Technology used to improve such products as components of gas turbines and turbopumps and of other shaft/disk parts for powerplants, drive trains, or static structures.

  10. 31. FORGE, ANVIL, POWER FORGE HAMMER (FRONT TO BACK), AND ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    31. FORGE, ANVIL, POWER FORGE HAMMER (FRONT TO BACK), AND DOORWAY INTO MAIN SHOP-LOOKING SOUTHWEST. - W. A. Young & Sons Foundry & Machine Shop, On Water Street along Monongahela River, Rices Landing, Greene County, PA

  11. The effect of deformation rate on JBK-75 stainless steel forgings

    SciTech Connect

    Odegard, B.C.

    1987-10-01

    A parametric study was conducted to evaluate the effect of forging rate and forging temperature on the strength and microstructure of a precipitation-hardened, austenitic stainless steel forging. High and low forging rates were achieved using a high energy rate forging (HERF) process and a low velocity mechanical press (MP) respectively. The forging geometry required a two-stage forging sequence. The first stage or preform was identical for both forging processes. The final stage used similar die geometries with minor modifications to accommodate the attachment to the respective hammers. The resulting microstructure and mechanical properties were significantly different. These differences are attributed to the effects of strain rate and temperature. 10 figs., 1 tab.

  12. Fallon FORGE Well Lithologies

    DOE Data Explorer

    Doug Blankenship

    2016-03-01

    x,y,z text file of the downhole lithologic interpretations in the wells in and around the Fallon FORGE site. All the relevant information is in the file header (the spatial reference, the projection etc.) In addition all the fields in the data file are identified in the header.

  13. Near-Net Forging Technology Demonstration Program

    NASA Technical Reports Server (NTRS)

    Hall, I. Keith

    1996-01-01

    Significant advantages in specific mechanical properties, when compared to conventional aluminum (Al) alloys, make aluminum-lithium (Al-Li) alloys attractive candidate materials for use in cryogenic propellant tanks and dry bay structures. However, the cost of Al-Li alloys is typically five times that of 2219 aluminum. If conventional fabrication processes are employed to fabricate launch vehicle structure, the material costs will restrict their utilization. In order to fully exploit the potential cost and performance benefits of Al-Li alloys, it is necessary that near-net manufacturing methods be developed to off-set or reduce raw material costs. Near-net forging is an advanced manufacturing method that uses elevated temperature metal movement (forging) to fabricate a single piece, near-net shape, structure. This process is termed 'near-net' because only a minimal amount of post-forge machining is required. The near-net forging process was developed to reduce the material scrap rate (buy-to-fly ratio) and fabrication costs associated with conventional manufacturing methods. The goal for the near-net forging process, when mature, is to achieve an overall cost reduction of approximately 50 percent compared with conventional manufacturing options for producing structures fabricated from Al-Li alloys. This NASA Marshall Space Flight Center (MSFC) sponsored program has been a part of a unique government / industry partnership, coordinated to develop and demonstrate near-net forging technology. The objective of this program was to demonstrate scale-up of the near-net forging process. This objective was successfully achieved by fabricating four integrally stiffened, 170- inch diameter by 20-inch tall, Al-Li alloy 2195, Y-ring adapters. Initially, two 2195 Al-Li ingots were converted and back extruded to produce four cylindrical blockers. Conventional ring rolling of the blockers was performed to produce ring preforms, which were then contour ring rolled to produce

  14. Selection of informative parameters of vibroacoustic processes

    NASA Technical Reports Server (NTRS)

    Koshek, L. N.

    1973-01-01

    The problem of selecting informative parameters of vibro-acoustic processes and the construction of apparatus for their determination are discussed. It is assumed that the processes being investigated are structurally uniform and either purely random or contain not very many determinative components.

  15. Friction and wear in hot forging of steels

    SciTech Connect

    Daouben, E.; Dubar, L.; Dubar, M.; Deltombe, R.; Dubois, A.; Truong-Dinh, N.; Lazzarotto, L.

    2007-04-07

    In the field of hot forging of steels, the mastering of wear phenomena enables to save cost production, especially concerning tools. Surfaces of tools are protected thanks to graphite. The existing lubrication processes are not very well known: amount and quality of lubricant, lubrication techniques have to be strongly optimized to delay wear phenomena occurrence. This optimization is linked with hot forging processes, the lubricant layers must be tested according to representative friction conditions. This paper presents the first part of a global study focused on wear phenomena encountered in hot forging of steels. The goal is the identification of reliable parameters, in order to bring knowledge and models of wear. A prototype testing stand developed in the authors' laboratory is involved in this experimental analysis. This test is called Warm and Hot Upsetting Sliding Test (WHUST). The stand is composed of a heating induction system and a servo-hydraulic system. Workpieces taken from production can be heated until 1200 deg. C. A nitrided contactor representing the tool is heated at 200 deg. C. The contactor is then coated with graphite and rubs against the workpiece, leaving a residual track on it. Friction coefficient and surface parameters on the contactor and the workpiece are the most representative test results. The surface parameters are mainly the sliding length before defects occurrence, and the amplitude of surface profile of the contactor. The developed methodology will be first presented followed by the different parts of the experimental prototype. The results of experiment show clearly different levels of performance according to different lubricants.

  16. Flow simulation and solidification phenomena of AC4CH aluminum alloy in semi-solid forging process by explicit MPS method

    NASA Astrophysics Data System (ADS)

    Regmi, Amit; Shintaku, Hiroki; Sasaki, Tsutomu; Koshizuka, Seiichi

    2015-09-01

    Semi-solid forging (SSF) is a powerful manufacturing technology to fabricate near-net shaped products in automotive industries. During SSF process, the filling behavior and solidification process of AC4CH aluminum alloy is presented in this paper. The explicit MPS method program solving Navier-Stokes equation is coupled with heat transfer and solidification has been used to predict the filling pattern and temperature distribution of semi-solid material (SSM). The non-Newtonian rheological model was used as the constitutive equation of SSM. In this study, numerical analysis of SSF was carried out in box cavity with various flange thickness (4, 8, 12 and 16 mm) and corresponding experiments were undertaken for AC4CH aluminum alloy with solid fraction less than 0.5. The numerical results of SSM filling pattern and solidification phenomena in flange were validated with the experimental results. During solidification process, flow calculation was stopped and only thermal calculation was carried out. The shrinkage defect was well predicted near the lower mid area of the box cavity with flange thickness 16 mm.

  17. Hot Cutting of Real-Time Cast-Forged GS Ductile Iron for Automotive Rods

    NASA Astrophysics Data System (ADS)

    Fouilland, Laurence; Mansori, Mohamed El

    2011-01-01

    In the global economy context, automotive industry suppliers have to keep a constant advance on products design and manufacturing process. Concerning automotive rods, the substitution of forged steel by spherical graphite iron (SG iron) with high mechanical properties constitutes a valid economic alternative. Such rods are produced using a complex coupled process: casting and forging followed by an austempered heat treatment. The forging operation is capable to shape the cast rod which introduces hot deformation to increase mechanical properties of net-shape SG iron rod. However, the intermediate re-heating between casting and forging must be avoided to keep competitive manufacturing costs. A major concern of this new process development is the cracks produced in rod's surface which are consecutive to hot spruing involved after casting operations. This issue is addressed in this paper which discusses the physical mechanisms involved in the hot ductile damage of SG iron. Hot cutting tests were performed to simulate the spruing operation which shows the close interactions between microstructure, machining parameters and resulting damages. The damage mechanisms in terms of crack initiation and its growth have been studied with respect to the constituent phases (austenite+graphite nodules), the cut surface morphology and the hot cutting performance.

  18. Superplastic forging nitride ceramics

    DOEpatents

    Panda, Prakash C.; Seydel, Edgar R.; Raj, Rishi

    1988-03-22

    The invention relates to producing relatively flaw free silicon nitride ceramic shapes requiring little or no machining by superplastic forging This invention herein was made in part under Department of Energy Grant DE-AC01-84ER80167, creating certain rights in the United States Government. The invention was also made in part under New York State Science and Technology Grant SB1R 1985-10.

  19. A material based approach to creating wear resistant surfaces for hot forging

    NASA Astrophysics Data System (ADS)

    Babu, Sailesh

    . Dissertation outlines development of a new cyclic contact test design to recreate intermittent tempering seen in hot forging. This test has been used to validate the use of tempering parameters in modeling of in-service softening of tool steel surfaces. The dissertation also outlines an industrial case study, conducted at a forging company, to validate the wear model. This dissertation also outlines efforts at Ohio State University, to deposit Nickel Aluminide on AISI H13 substrate, using Laser Engineered Net Shaping (LENS). Dissertation reports results from an array of experiments conducted using LENS 750 machine, at various power levels, table speeds and hatch spacing. Results pertaining to bond quality, surface finish, compositional gradients and hardness are provided. Also, a thermal-based finite element numerical model that was used to simulate the LENS process is presented, along with some demonstrated results.

  20. Surveillance of industrial processes with correlated parameters

    DOEpatents

    White, A.M.; Gross, K.C.; Kubic, W.L.; Wigeland, R.A.

    1996-12-17

    A system and method for surveillance of an industrial process are disclosed. The system and method includes a plurality of sensors monitoring industrial process parameters, devices to convert the sensed data to computer compatible information and a computer which executes computer software directed to analyzing the sensor data to discern statistically reliable alarm conditions. The computer software is executed to remove serial correlation information and then calculate Mahalanobis distribution data to carry out a probability ratio test to determine alarm conditions. 10 figs.

  1. Surveillance of industrial processes with correlated parameters

    DOEpatents

    White, Andrew M.; Gross, Kenny C.; Kubic, William L.; Wigeland, Roald A.

    1996-01-01

    A system and method for surveillance of an industrial process. The system and method includes a plurality of sensors monitoring industrial process parameters, devices to convert the sensed data to computer compatible information and a computer which executes computer software directed to analyzing the sensor data to discern statistically reliable alarm conditions. The computer software is executed to remove serial correlation information and then calculate Mahalanobis distribution data to carry out a probability ratio test to determine alarm conditions.

  2. Modeling and simulation of austenite grain evolution for heavy forging steel 30Cr2Ni4MoV undergoing hot deformation

    NASA Astrophysics Data System (ADS)

    Cui, Zhenshan; Li, Cuidong; Chen, Fei; Sui, Dashan

    2013-05-01

    30Cr2Ni4MoV is widely used as heavy forging materials for low pressure rotors which equips the ultra-supercritical power generations. The final properties of the heavy forging products relies apparently on the grain size of the material, so that the grain should be refined and homogenized during forming process through controlling the working parameters during forming process. For this purpose, the research on the modeling and simulation of austenite grain evolution is conducted for different forming stages: the grain growth during heating, dynamic recrystallization (DRX) during hitting, and meta-dynamic (MDRX) and static recrystallization (SRX) during hitting intervals. Experiment-based phenomenological models, as easy ways to characterize the grain evolution, are established for the process of heating and single-hit, while the Cellular Automaton simulations are applied for tracing more complex recrystallization process during multi-hit deformations. The research shows that, for heavy forgings, the long-time heating process can cause very coarse grains which are harmful to the final properties. Therefore, in order to refine and homogenize the grain size for the heavy forgings, the working parameters for forging should be determined to ensure the recrystallization can be completed and the deformation can be uniformly distributed. Some applications of the models and simulation method in multi-hit process are also demonstrated.

  3. Computer-Aided Design of Manufacturing Chain Based on Closed Die Forging for Hardly Deformable Cu-Based Alloys

    NASA Astrophysics Data System (ADS)

    Pietrzyk, Maciej; Kuziak, Roman; Pidvysots'kyy, Valeriy; Nowak, Jarosław; Węglarczyk, Stanisław; Drozdowski, Krzysztof

    2013-07-01

    Two copper-based alloys were considered, Cu-1 pct Cr and Cu-0.7 pct Cr-1 pct Si-2 pct Ni. The thermal, electrical, and mechanical properties of these alloys are given in the paper and compared to pure copper and steel. The role of aging and precipitation kinetics in hardening of the alloys is discussed based upon the developed model. Results of plastometric tests performed at various temperatures and various strain rates are presented. The effect of the initial microstructure on the flow stress was investigated. Rheologic models for the alloys were developed. A finite element (FE) model based on the Norton-Hoff visco-plastic flow rule was applied to the simulation of forging of the alloys. Analysis of the die wear for various processes of hot and cold forging is presented as well. A microstructure evolution model was implemented into the FE code, and the microstructure and mechanical properties of final products were predicted. Various variants of the manufacturing cycles were considered. These include different preheating schedules, hot forging, cold forging, and aging. All variants were simulated using the FE method and loads, die filling, tool wear, and mechanical properties of products were predicted. Three variants giving the best combination of forging parameters were selected and industrial trials were performed. The best manufacturing technology for the copper-based alloys is proposed.

  4. Effect of Variants of Thermomechanical Working and Annealing Treatment on Titanium Alloy Ti6Al4V Closed Die Forgings

    NASA Astrophysics Data System (ADS)

    Gupta, R. K.; Kumar, V. Anil; Kumar, P. Ram

    2016-06-01

    Performance of titanium alloy Ti6Al4V pressure vessels made of closed die forged domes of route `B' (multiple step forged and mill annealed) is reported to be better than route `A' (single/two step forged and mill annealed). Analysis revealed that forgings processed through route `B' have uniformity in microstructure and yield strength at various locations within the forging, as compared to that of route `A.' It is attributed to in-process recrystallization (dynamic as well as static) of route `B' forgings as compared to limited recrystallization of route `A' forgings. Further, post-forging recrystallization annealing (RA) effect is found to be more significant for route `A' forgings in achieving uniform microstructure and mechanical properties, since route `B' forgings have already undergone similar phenomenon during the thermomechanical working process itself. Considering prime importance of yield strength, statistical scatter in yield strength values within the forgings have been evaluated for forgings of both the routes. Standard deviation in the yield strength of route `B' forgings was lower (<10 MPa) as compared to route `A' (>15 MPa), which later became lower (~10 MPa) after RA with a minor decrease in yield strength. The present work discusses these variants of thermomechanical processing along with annealing to achieve better uniformity in properties and microstructure.

  5. Forging of compressor blades: Temperature and ram velocity effects

    SciTech Connect

    Saigal, A.; Zhen, K.; Chan, T.S.

    1995-07-01

    Forging is one of the most widely used manufacturing process for making high-strength, structurally integrated, impact and creep-resistant Ti-6Al-4V compressor blades for jet engines. In addition, in modern metal forming technology, finite element analysis method and computer modeling are being extensively employed for initial evaluation and optimization of various processes, including forging. In this study, DEFORM, a rigid viscoplastic two-dimensional finite element code was used to study the effects of initial die temperature and initial ram velocity on the forging process. For a given billet, die temperature and ram velocity influence the strain rate, temperature distribution,and thus the flow stress of the material. The die temperature and the ram velocity were varied over the range 300 to 700 F and 15--25 in./sec, respectively, to estimate the maximum forging load and the total energy required to forge compressor blades. The ram velocity was assumed to vary linearly as a function of stroke. Based on the analysis,it was found the increasing the die temperature from 300 to 700 F decreases the forging loads by 19.9 percent and increases the average temperature of the workpiece by 43 F. Similarly, increasing the initial ram velocity from 15 to 25 in./sec decreases the forging loads by 25.2 percent and increases the average temperature of the workpiece by 36 F. The nodal temperature distribution is bimodal in each case. The forging energy required to forge the blades is approximately 18 kips *in./in.

  6. Visual parameter optimisation for biomedical image processing

    PubMed Central

    2015-01-01

    Background Biomedical image processing methods require users to optimise input parameters to ensure high-quality output. This presents two challenges. First, it is difficult to optimise multiple input parameters for multiple input images. Second, it is difficult to achieve an understanding of underlying algorithms, in particular, relationships between input and output. Results We present a visualisation method that transforms users' ability to understand algorithm behaviour by integrating input and output, and by supporting exploration of their relationships. We discuss its application to a colour deconvolution technique for stained histology images and show how it enabled a domain expert to identify suitable parameter values for the deconvolution of two types of images, and metrics to quantify deconvolution performance. It also enabled a breakthrough in understanding by invalidating an underlying assumption about the algorithm. Conclusions The visualisation method presented here provides analysis capability for multiple inputs and outputs in biomedical image processing that is not supported by previous analysis software. The analysis supported by our method is not feasible with conventional trial-and-error approaches. PMID:26329538

  7. The production of grain oriented lanthanum titanate (La{sub 2}Ti{sub 2}O{sub 7}) ceramics by uniaxial hot-forging process for improved fracture toughness

    SciTech Connect

    Ceylan, Ali

    2008-07-01

    The layered-structural ceramics, such as lanthanum titanate (La{sub 2}Ti{sub 2}O{sub 7}), have been known for their good electrical and optical properties at high frequencies and temperatures. However, few studies have been conducted on the mechanical properties of these ceramics. The interest in ceramic hot-forging (HF) has been greatly increased recently due to the enhancement in fracture toughness via bridging effect of oriented grains. In this study, grain oriented lanthanum titanate was produced by the hot-forging process. The characterizations of the samples were achieved by density measurement, scanning electron microscopy (SEM), optical microscopy, X-ray diffraction (XRD), Vickers indentation and three-point bending test. According to X-ray diffraction patterns, the orientation factor (f) was found to be 0.73 for certain hot-forging conditions resulting an improved fracture toughness. The improved fracture toughness of La{sub 2}Ti{sub 2}O{sub 7} (3.2 MPa m{sup 1/2}) reached to the value of monolithic alumina (Al{sub 2}O{sub 3}) between 3 and 4 MPa m{sup 1/2}.

  8. Effects of process parameters on hydrothermal carbonization

    NASA Astrophysics Data System (ADS)

    Uddin, Md. Helal

    In recent years there has been increased research activity in renewable energy, especially upgrading widely available lignicellulosic biomass, in a bid to counter the increasing environmental concerns related with the use of fossil fuels. Hydrothermal carbonization (HTC), also known as wet torrefaction or hot water pretreatment, is a process for pretreatment of diverse lignocellulosic biomass feedstocks, where biomass is treated under subcritical water conditions in short contact time to produce high-value products. The products of this process are: a solid mass characterized as biochar/biocoal/biocarbon, which is homogeneous, energy dense, and hydrophobic; a liquid stream composed of five and six carbon sugars, various organic acids, and 5-HMF; and a gaseous stream, mainly CO2. A number of process parameters are considered important for the extensive application of the HTC process. Primarily, reaction temperature determines the characteristics of the products. In the solid product, the oxygen carbon ratio decreases with increasing reaction temperature and as a result, HTC biochar has the similar characteristics to low rank coal. However, liquid and gaseous stream compositions are largely correlated with the residence time. Biomass particle size can also limit the reaction kinetics due to the mass transfer effect. Recycling of process water can help to minimize the utility consumption and reduce the waste treatment cost as a result of less environmental impact. Loblolly pine was treated in hot compressed water at 200 °C, 230 °C, and 260 °C with 5:1 water:biomass mass ratio to investigate the effects of process parameters on HTC. The solid product were characterized by their mass yields, higher heating values (HHV), and equilibrium moisture content (EMC), while the liquid were characterized by their total organic carbon content and pH value.

  9. Modeling microstructural development during the forging of Waspaloy

    NASA Astrophysics Data System (ADS)

    Shen, Gangshu; Semiatin, S. L.; Shivpuri, Rajiv

    1995-07-01

    A model for predicting the evolution of microstructure in Waspaloy during thermomechanical proc-essing was developed in terms of dynamic recrystallization (DRX), metadynamic recrystallization, and grain growth phenomena. Three sets of experiments were conducted to develop the model: (1) preheating tests to model grain growth prior to hot deformation; (2) compression tests in a Gleeble testing machine with different deformation and cooling conditions to model DRX, metadynamic recrystallization, and short time grain growth during the post deformation dwell period and cooling; and (3) pancake and closed die forging tests conducted in a manufacturing environment to verify and refine the model. The microstructural model was combined with finite element modeling (FEM) to predict microstructure development during forging of Waspaloy. Model predictions showed good agreement with microstructures obtained in actual isothermal and hammer forgings carried out at a forging shop.

  10. Modeling microstructural development during the forging of Waspaloy

    SciTech Connect

    Shen, G.; Shivpuri, R.; Semiatin, S.L.

    1995-07-01

    A model for predicting the evolution of microstructure in Waspaloy during thermomechanical processing was developed in terms of dynamic recrystallization (DRX), metadynamic recrystallization, and grain growth phenomena. Three sets of experiments were conducted to develop the model: (1) preheating tests to model grain growth prior to hot deformation; (2) compression tests in a Gleeble testing machine with different deformation and cooling conditions to model DRX, metadynamic recrystallization, and short time grain growth during the post deformation dwell period and cooling; and (3) pancake and closed die forging tests conducted in a manufacturing environment to verify and refine the model. The microstructural model was combined with finite element modeling (FEM) to predict microstructure development during forging of Waspaloy. Model predictions showed good agreement with microstructures obtained in actual isothermal and hammer forgings carried out at a forging shop.

  11. Automatic feature extraction from micrographs of forged superalloys

    NASA Astrophysics Data System (ADS)

    Berhuber, E.; Rinnhofer, A.; Stockinger, M.; Benesova, W.; Jakob, G.

    2008-07-01

    The manual determination of metallurgical parameters of forged superalloys can be dramatically improved by automatic, image-processing-based feature extraction. With the proposed methods, the typical errors during grain size estimation for Inconel 718 and Allvac 718Plus ™ , caused by twins and other artifacts like scratches, can be eliminated. Different processing strategies for grain size estimation allow the application of a wide range of ASTM grain size numbers from G3 to G12 with the typical variations in the manifestation of metallurgical details and the magnification-related limitations of image quality. Intercept counting strategies show advantages for samples with pronounced anisotropy and can produce detailed statistics on grain orientation. In addition to a single grain size number, grain size histograms offer a more precise description of the material properties.

  12. Fitting function representation for strain fields and its application to the optimizing process

    NASA Astrophysics Data System (ADS)

    Chen, Kun; Liu, Ke-jia; Wei, Li-qun; Yang, Yi-tao

    2014-06-01

    A fitted function method to describe the strain fields during forging was discussed to optimize the homogeneous distribution of strain in the axial forging zones during successive stretching. The results are verified by experiment and numerical simulation, and the deviations between experiment and simulation are less than 24%. Therefore, the fitted function method can be applied to optimize the stretching process for large forgings. The optimal value of feed determined by the analytic method ensures that the degree of inhomogeneity in strain in the axial ingot zone is less than 6%. This work provides a mathematic model to optimize technological parameters in stretch forging of large ingots.

  13. Prediction of Microstructure in High-Strength Ductile Forging Parts

    SciTech Connect

    Urban, M.; Back, A.; Hirt, G.; Keul, C.; Bleck, W.

    2010-06-15

    Governmental, environmental and economic demands call for lighter, stiffer and at the same time cheaper products in the vehicle industry. Especially safety relevant parts have to be stiff and at the same time ductile. The strategy of this project was to improve the mechanical properties of forging steel alloys by employing a high-strength and ductile bainitic microstructure in the parts while maintaining cost effective process chains to reach these goals for high stressed forged parts. Therefore, a new steel alloy combined with an optimized process chain has been developed. To optimize the process chain with a minimum of expensive experiments, a numerical approach was developed to predict the microstructure of the steel alloy after the process chain based on FEM simulations of the forging and cooling combined with deformation-time-temperature-transformation-diagrams.

  14. West Flank Coso, CA FORGE Seismic Reflection

    DOE Data Explorer

    Doug Blankenship

    2016-05-16

    PDFs of seismic reflection profiles 101,110, 111 local to the West Flank FORGE site. 45 line kilometers of seismic reflection data are processed data collected in 2001 through the use of vibroseis trucks. The initial analysis and interpretation of these data was performed by Unruh et al. (2001). Optim processed these data by inverting the P-wave first arrivals to create a 2-D velocity structure. Kirchhoff images were then created for each line using velocity tomograms (Unruh et al., 2001).

  15. 48 CFR 225.7102 - Forgings.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 48 Federal Acquisition Regulations System 3 2011-10-01 2011-10-01 false Forgings. 225.7102 Section 225.7102 Federal Acquisition Regulations System DEFENSE ACQUISITION REGULATIONS SYSTEM, DEPARTMENT OF... Forgings....

  16. 48 CFR 225.7102 - Forgings.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 48 Federal Acquisition Regulations System 3 2012-10-01 2012-10-01 false Forgings. 225.7102 Section 225.7102 Federal Acquisition Regulations System DEFENSE ACQUISITION REGULATIONS SYSTEM, DEPARTMENT OF... Forgings....

  17. 48 CFR 225.7102 - Forgings.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 48 Federal Acquisition Regulations System 3 2013-10-01 2013-10-01 false Forgings. 225.7102 Section 225.7102 Federal Acquisition Regulations System DEFENSE ACQUISITION REGULATIONS SYSTEM, DEPARTMENT OF... Forgings....

  18. 48 CFR 225.7102 - Forgings.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 48 Federal Acquisition Regulations System 3 2010-10-01 2010-10-01 false Forgings. 225.7102 Section 225.7102 Federal Acquisition Regulations System DEFENSE ACQUISITION REGULATIONS SYSTEM, DEPARTMENT OF... Forgings....

  19. 48 CFR 225.7102 - Forgings.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 48 Federal Acquisition Regulations System 3 2014-10-01 2014-10-01 false Forgings. 225.7102 Section 225.7102 Federal Acquisition Regulations System DEFENSE ACQUISITION REGULATIONS SYSTEM, DEPARTMENT OF... Forgings....

  20. Investigations on Forging Dies with Ceramic Inserts by means of Finite-Element-Analysis

    SciTech Connect

    Behrens, B.-A.; Schaefer, F.; Bistron, M.

    2007-05-17

    The tools in hot forging processes are exposed to high thermal and mechanical loadings. Tempering of the tool edge layer occurs as a result of thermal loadings. This leads to a gradual hardness loss of the tool material and increase of wear over forging cycles. Hence, the tool life in hot forging is mainly limited by wear. An extension of the die service life can be achieved by the use of ceramic inserts. The integration of ceramics into the die base plate made of hot-work steel is realised by active brazing, whereby it possible to apply ceramic in region with high wear. It has to be ensured in the design process of ceramic inserts for forging dies that no critical tensile stresses occur in the ceramics. A reliable design of the ceramic inserts is possible only through consideration of brazing and forming process. The development of a Finite-Element-model for the design of forging dies with ceramic inserts is the intention of the work presented in this paper. At first the forging process with a conventional die is analyzed concerning abrasive die wear to identify regions with high wear risk applying a modified Archard model. Based on the results of wear calculation, a forging die with ceramic inserts is investigated in terms of joint stresses at the end of the active brazing process. Subsequently, the forging process considering the residual stresses caused by joining is simulated in order to obtain the die stress in use.

  1. Advanced rotor forgings for high-temperature steam turbines. Volume 1. Ingot and forging production. Final report

    SciTech Connect

    Swaminathan, V.P.; Steiner, J.E.; Mitchell, A.

    1986-05-01

    Three advanced steel-melting processes - low-sulfur vacuum silicon deoxidation, electroslag remelting, and vacuum carbon deoxidation (VCD) - were applied to produce three CrMoV (ASTM A470, Class 8) steel forgings for steam turbine application. Ingots weighing about 100 t each were produced using these three processes, and rotors were forged with final weights of about 30 t each. Compared to the conventionally produced forgings, the advanced technology forgings show better tensile ductility and better uniformity along the radial and longitudinal directions. Charpy upper-shelf energy shows about 40% improvement, and no temper embrittlement was found using step-cooled and isothermal-aging treatments. Significant improvement in fracture toughness (K/sub IC/ and J/sub IC/) is realized for these forgings. Low-cycle fatigue life is better at high temperatures because of the absence of nonmetallic inclusions. Creep strength shows slight improvement. However, creep ductility is improved, probably because of low residual elements. The VCD forgings show excellent creep ductility, even with long lives. Both the toughness and creep properties are equal to or better than those of oil-quenched rotors produced by European practices. These improvements are attributed to cleaner steel, better control of ingot solidification, low residual elements (especially very low sulfur content), and the associated reduction of nonmetallic inclusions. These three rotors have been placed in service in three operating power plants in units rated at 520 MW each. Volume 1 of this report covers ingot and forging production, and volume 2 covers mechanical property evaluation.

  2. Effect of processing parameters on autoclaved PMR polyimide composites

    NASA Technical Reports Server (NTRS)

    Vannucci, R. D.

    1977-01-01

    A study was conducted to determine the effect of processing parameters on the processability and properties of autoclaved fiber reinforced PMR polyimide composites. Composites were fabricated from commercially available graphite fabric and glass fabric PMR polyimide prepreg materials. Process parameters investigated included degree of resin advancement, heating rate, and cure pressure. Composites were inspected for porosity by ultrasonic C scan and photomicrographic examination. Processing characteristics for each set of process parameters and the effect of process parameters on composite mechanical properties at room temperature and 600 F are described.

  3. A New Method for Controlling Billet Temperature During Isothermal Die Forging of a Complex Superalloy Casing

    NASA Astrophysics Data System (ADS)

    Lin, Y. C.; Wu, Xian-Yang

    2015-09-01

    Isothermal die forging is one of near net-shape metal-forming technologies. Strict control of billet temperature during isothermal die forging is a guarantee for the excellent properties of final product. In this study, a new method is proposed to accurately control the billet temperature of complex superalloy casing, based on the finite element simulation and response surface methodology (RSM). The proposed method is accomplished by the following two steps. Firstly, the thermal compensation process is designed and optimized to overcome the inevitable heat loss of dies during hot forging. i.e., the layout and opening time of heaters assembled on die sleeves are optimized. Then, the effects of forging speed (the pressing velocity of hydraulic machine) and its changing time on the maximum billet temperature are discussed. Furthermore, the optimized forging speed and its changing time are obtained by RSM. Comparisons between the optimized and conventional die forging processes indicate that the proposed method can effectively control the billet temperature within the optimal forming temperature range. So, the optimized die forging processes can guarantee the high volume fraction of dynamic recrystallization, and restrict the rapid growth of grains in the forged superalloy casing.

  4. Study on the Hot Processing Parameters-Impact Toughness Correlation of Ti-6Al-4V Alloy

    NASA Astrophysics Data System (ADS)

    Shi, Xiaohui; Zeng, Weidong; Sun, Yu; Han, Yuanfei; Zhao, Yongqing

    2016-04-01

    In this research, the hot processing parameters-impact toughness correlation of Ti-6Al-4V titanium alloy is studied. Fifty-four groups of hot processing treatments with different forging temperatures (930, 950, 970 °C), deformation degrees (20, 50, 80%), annealing temperatures (600, 700, 800 °C), and annealing time (1 and 5 h) were conducted. The orthogonal design was used to find the primary hot processing parameters influencing the impact toughness of Ti-6Al-4V alloy. The results show that the annealing temperature can exert the biggest influence on impact toughness. Low annealing temperature is essential to achieve high impact toughness value. In addition, the BP neural network was used to describe the quantitative correlation between hot processing parameters and impact toughness. The results show that the BP neural network exhibits good performance in predicting the impact toughness of Ti-6Al-4V alloy. The prediction error is within 5%. The BP neural network and the orthogonal design method are mutually confirmed in the present work. Finally, based on the microstructure analysis, the reasons responsible for above experimental results are explained.

  5. Study on the Hot Processing Parameters-Impact Toughness Correlation of Ti-6Al-4V Alloy

    NASA Astrophysics Data System (ADS)

    Shi, Xiaohui; Zeng, Weidong; Sun, Yu; Han, Yuanfei; Zhao, Yongqing

    2016-05-01

    In this research, the hot processing parameters-impact toughness correlation of Ti-6Al-4V titanium alloy is studied. Fifty-four groups of hot processing treatments with different forging temperatures (930, 950, 970 °C), deformation degrees (20, 50, 80%), annealing temperatures (600, 700, 800 °C), and annealing time (1 and 5 h) were conducted. The orthogonal design was used to find the primary hot processing parameters influencing the impact toughness of Ti-6Al-4V alloy. The results show that the annealing temperature can exert the biggest influence on impact toughness. Low annealing temperature is essential to achieve high impact toughness value. In addition, the BP neural network was used to describe the quantitative correlation between hot processing parameters and impact toughness. The results show that the BP neural network exhibits good performance in predicting the impact toughness of Ti-6Al-4V alloy. The prediction error is within 5%. The BP neural network and the orthogonal design method are mutually confirmed in the present work. Finally, based on the microstructure analysis, the reasons responsible for above experimental results are explained.

  6. The development and production of thermo-mechanically forged tool steel spur gears

    NASA Technical Reports Server (NTRS)

    Bamberger, E. N.

    1973-01-01

    A development program to establish the feasibility and applicability of high energy rate forging procedures to tool steel spur gears was performed. Included in the study were relatively standard forging procedures as well as a thermo-mechanical process termed ausforming. The subject gear configuration utilized was essentially a standard spur gear having 28 teeth, a pitch diameter of 3.5 inches and a diametral pitch of 8. Initially it had been planned to use a high contact ratio gear design, however, a comprehensive evaluation indicated that severe forging problems would be encountered as a result of the extremely small teeth required by this type of design. The forging studies were successful in achieving gear blanks having integrally formed teeth using both standard and thermo-mechanical forging procedures.

  7. HYDROGEN-ASSISTED FRACTURE IN FORGED TYPE 304L AUSTENITIC STAINLESS STEEL

    SciTech Connect

    Switzner, Nathan; Neidt, Ted; Hollenbeck, John; Knutson, J.; Everhart, Wes; Hanlin, R.; Bergen, R.; Balch, D. K.

    2012-09-06

    Austenitic stainless steels generally have good resistance to hydrogen-assisted fracture; however, structural designs for high-pressure gaseous hydrogen are constrained by the low strength of this class of material. Forging is used to increase the low strength of austenitic stainless steels, thus improving the efficiency of structural designs. Hydrogen-assisted racture, however, depends on microstructural details associated with manufacturing. In this study, hydrogen-assisted fracture of forged type 304L austenitic stainless steel is investigated. Microstructural variation in multi-step forged 304L was achieved by forging at different rates and temperatures, and by process annealing. High internal hydrogen content in forged type 304L austenitic stainless steel is achieved by thermal precharging in gaseous hydrogen and results in as much as 50% reduction of tensile ductility.

  8. Implementation of state-of-the-art rotor forging evaluation to manage the oldest rotor fleet in the USA

    SciTech Connect

    Puri, A.; Steakley, M.; McCann, D.

    1995-12-31

    The average age of the Tennessee Valley Authority`s (TVA) fossil fleet is almost 40 years with a large population of ``C`` grade rotors manufactured in the 1950`s. Until 1991, TVA relied upon the OEM`s to support the rotor forging assessment and establish the reinspection intervals. Based on the OEM`s recommendations most turbine/generator overhauls were governed by the forging reinspection interval. In the spring of 1992, TVA initiated an engineered forging evaluation process that involved state-of-the-art amplitude independent, target-motion based Ultrasonic And Data Processing System (UDRPS) forging inspection, forging material sampling, and fracture mechanics analysis. This paper outlines TVA`s state-of-art rotor forging evaluation program, results achieved since its introduction and the long range benefits to TVA.

  9. Fallon FORGE Well Temp data

    DOE Data Explorer

    Doug Blankenship

    2016-03-01

    x,y,z downhole temperature data for wells in and around the Fallon FORGE site. Data for the following wells are included: 82-36, 82-19, 84.31, 61-36, 88-24, FOH-3D, FDU-1, and FDU-2. Data are formatted in txt format and in columns for importing into Earthvision Software. Column headers and coordinate system information is stored in the file header.

  10. Thermo-mechanical modeling of the electrically-assisted manufacturing (EAM) technique during open die forging

    NASA Astrophysics Data System (ADS)

    Salandro, Wesley A.

    This thesis contains all of the steps which allow the Electrically-Assisted Manufacturing (EAM) technique to be experimentally explored and analytically modeled for an electrically-assisted forging operation. Chapter 1 includes the problem statement, proposed solution, and literature reviews on EAM. Chapter 2 describes a thorough background on the EAM technique, highlights prior EAM research, and explains the research approach taken for this thesis. The coupled thermo-mechanical modeling strategy, along with the introduction of the Electroplastic Effect Coefficient (EEC) is provided in Chapter 3. Chapter 4 explains the two different approaches to determine the EEC profiles when modeling a particular metal. The simplified EAF mechanical model for electrically-assisted forging is presented in Chapter 5. Also in this chapter, the same modeling methodology (i.e. thermo-mechanical, EEC, etc.) is used to predict loads for an electrically-assisted bending (EAB) process. The following chapters explore how different material- and process-based parameters affect the EAF technique. Chapter 6 examines how different workpiece contact areas affect EAF effectiveness, along with an exploration of how well different metal forming lubricants perform with EAF. Chapter 7 explores if there is a difference in the thermal or mechanical profiles of specimens undergoing EAF forging tests with different average grain sizes. Chapter 8 examines the same effects as the previous chapter on specimens with varying levels of prior cold work. The materials- and process-based simplifications and sensitivities of the proposed modeling strategy are outlined in Chapter 9. Chapters 10-14 include the science behind the electroplastic effect, conclusions, future work, broader impacts, and intellectual merit, respectively. The overall intention of this thesis is to show the candidate's ability to take an idea for a new manufacturing process, prove that it works, and then understand and model the process

  11. Structure and Mechanical Properties of Nitrogen Austenitic Steel after Ultrasonic Forging

    NASA Astrophysics Data System (ADS)

    Narkevich, N. A.; Tolmachev, A. I.; Vlasov, I. V.; Surikova, N. S.

    2016-03-01

    Electron microscopy and X-ray diffraction have been used to investigate a nitrogen 07Kh17AG18 steel with an austenitic structure after the surface deformation treatment—ultrasonic forging. During ultrasonic forging, an austenitic structure transforms into a new structure with an elevated concentration of deformation-induced stacking faults, a lot of deformation microtwins, ɛ-martensite crystals. The austenite lattice parameter is found to be decreased in the surface layer. After ultrasonic forging, nitrided steel exhibits enhanced strength properties with retained high plasticity.

  12. Assessment of NASA Dual Microstructure Heat Treatment Method for Multiple Forging Batch Heat Treatment

    NASA Technical Reports Server (NTRS)

    Gayda, John (Technical Monitor); Lemsky, Joe

    2004-01-01

    NASA dual microstructure heat treatment technology previously demonstrated on single forging heat treat batches of a generic disk shape was successfully demonstrated on a multiple disk batch of a production shape component. A group of four Rolls-Royce Corporation 3rd Stage AE2100 forgings produced from alloy ME209 were successfully dual microstructure heat treated as a single heat treat batch. The forgings responded uniformly as evidenced by part-to-part consistent thermocouple recordings and resultant macrostructures, and from ultrasonic examination. Multiple disk DMHT processing offers a low cost alternative to other published dual microstructure processing techniques.

  13. Laser-dispersing of forging tools using AlN-ceramics

    NASA Astrophysics Data System (ADS)

    Noelke, C.; Luecke, M.; Kaierle, S.; Wesling, V.; Overmeyer, L.

    2014-02-01

    Forging tools for aluminum work pieces show an increased adhesive wear due to cold welding during the forging process. Laser dispersing offers at this point a great potential to fabricate protective layers or tracks with tailored properties that reduce abrasive or adhesive wear at the surface of highly stressed components. Using different process strategies, four metal ceramic compounds applied on two substrate geometries were investigated regarding their structural and mechanical properties and their performance level. The subsequent forging tests have pointed out a positive effect and less adhesive residuals on the laser dispersed tool surface.

  14. Combining Noise Factors and Process Parameters in a Response Surface

    SciTech Connect

    Wyckoff, J.J.

    1998-03-19

    This presentation covers the strategy and analysis of an experiment to characterize a gas tungsten arc welding process. The experiment combined four uncontrolled noise factors and four controlled process parameters. A nontraditional response surface design was employed. Multiple responses were modeled. Optimal settings for the process parameters to successfully weld the widest range of the pertinent product features were identified. Thus, the process was made ''robust'' against ''noise'' factors. Comparisons are made between the experimental and analytical approach taken versus the Taguchi style of experimentation and analysis. This comparison is mainly done with respect to the information gained, such as product design criteria, incoming material specifications, and process adjustments for nonconforming material.

  15. Fuzzy control of the production environment process parameters

    NASA Astrophysics Data System (ADS)

    Izvekov, V. N.

    2015-04-01

    The fuzzy control process for support of given microclimatic production environment process parameters with loss of one from values, regulating regime of process was shown. The structural schematic decisions with algorithm of functioning and oriented to existing apparatus (means of realization) was presented.

  16. Parameter tuning of PVD process based on artificial intelligence technique

    NASA Astrophysics Data System (ADS)

    Norlina, M. S.; Diyana, M. S. Nor; Mazidah, P.; Rusop, M.

    2016-07-01

    In this study, an artificial intelligence technique is proposed to be implemented in the parameter tuning of a PVD process. Due to its previous adaptation in similar optimization problems, genetic algorithm (GA) is selected to optimize the parameter tuning of the RF magnetron sputtering process. The most optimized parameter combination obtained from GA's optimization result is expected to produce the desirable zinc oxide (ZnO) thin film from the sputtering process. The parameters involved in this study were RF power, deposition time and substrate temperature. The algorithm was tested to optimize the 25 datasets of parameter combinations. The results from the computational experiment were then compared with the actual result from the laboratory experiment. Based on the comparison, GA had shown that the algorithm was reliable to optimize the parameter combination before the parameter tuning could be done to the RF magnetron sputtering machine. In order to verify the result of GA, the algorithm was also been compared to other well known optimization algorithms, which were, particle swarm optimization (PSO) and gravitational search algorithm (GSA). The results had shown that GA was reliable in solving this RF magnetron sputtering process parameter tuning problem. GA had shown better accuracy in the optimization based on the fitness evaluation.

  17. Metal cutting analogy for establishing Friction Stir Welding process parameters

    NASA Astrophysics Data System (ADS)

    Stafford, Sylvester Allen

    A friction stir weld (FSW) is a solid state joining operation whose processing parameters are currently determined by lengthy trial and error methods. To implement FSWing rapidly in various applications will require an approach for predicting process parameters based on the physics of the process. Based on hot working conditions for metals, a kinematic model has been proposed for calculating the shear strain and shear strain rates during the FSW process, validation of the proposed model with direct measuring is difficult however. Since the shear strain and shear strain rates predicted for the FSW process, are similar to those predicted in metal cutting, validation of the FSW algorithms with microstructural studies of metal chips may be possible leading to the ability to predict FSW processing parameters.

  18. Effect of processing parameters on reaction bonding of silicon nitride

    NASA Technical Reports Server (NTRS)

    Richman, M. H.; Gregory, O. J.; Magida, M. B.

    1980-01-01

    Reaction bonded silicon nitride was developed. The relationship between the various processing parameters and the resulting microstructures was to design and synthesize reaction bonded materials with improved room temperature mechanical properties.

  19. Life Detection System DTIVA for Monitoring Parameter in Fossilization Process

    NASA Astrophysics Data System (ADS)

    Gómez, F.; Garcia-Descalzo, L.; Cockell, C. S.; Schwendner, P.; Rettberg, P.; Beblo-Vranesevic, K.; Bohmeier, M.; Rabbow, E.; Westall, F.; Gaboyer, F.; Walter, N.; Moissl-Eichinger, M.; Perras, A.; Amils, R.; Malki, M.; Ehrenfreund, P.; Monaghan, E.; Marteinsson, V.; Vannier, P.

    2016-05-01

    Using Life Detection System LDS we followed the physicochemical parameter in a growth culture under fossilization/mineralization-induced process with the objectives of biomarkers detection. Biomarkers study is crucial for the search for life on Mars.

  20. Reactor pressure vessel with forged nozzles

    DOEpatents

    Desai, Dilip R.

    1993-01-01

    Inlet nozzles for a gravity-driven cooling system (GDCS) are forged with a cylindrical reactor pressure vessel (RPV) section to which a support skirt for the RPV is attached. The forging provides enhanced RPV integrity around the nozzle and substantial reduction of in-service inspection costs by eliminating GDCS nozzle-to-RPV welds.

  1. 29 CFR 1910.218 - Forging machines.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 29 Labor 5 2010-07-01 2010-07-01 false Forging machines. 1910.218 Section 1910.218 Labor Regulations Relating to Labor (Continued) OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR OCCUPATIONAL SAFETY AND HEALTH STANDARDS Machinery and Machine Guarding § 1910.218 Forging machines. (a) General requirements—(1) Use of lead....

  2. Deformation Mechanisms in Tube Billets from Zr-1%Nb Alloy under Radial Forging

    SciTech Connect

    Perlovich, Yuriy; Isaenkova, Margarita; Fesenko, Vladimir; Krymskaya, Olga; Zavodchikov, Alexander

    2011-05-04

    Features of the deformation process by cold radial forging of tube billets from Zr-1%Nb alloy were reconstructed on the basis of X-ray data concerning their structure and texture. The cold radial forging intensifies grain fragmentation in the bulk of billet and increases significantly the latent hardening of potentially active slip systems, so that operation only of the single slip system becomes possible. As a result, in radially-forged billets unusual deformation and recrystallization textures arise. These textures differ from usual textures of {alpha}-Zr by the mutual inversion of crystallographic axes, aligned along the axis of tube.

  3. Sensitivities of bipolar junction transistor electrical parameters to processing variables

    NASA Astrophysics Data System (ADS)

    Abdulkarim, H. S.

    1980-03-01

    Variations and sensitivities of bipolar junction transistor (BJT) electrical parameters to processing variables were examined. The functional dependence of these sensitivities on the processing schedule employed was estimated. Some design criteria or guidelines that should be followed to reduce the sensitivities of electrical parameters and to minimize yield loss were determined. The BJT parameters considered were electrical parameters of the Ebers-Moll and hybrid-pi models, as well as some device parameters that were useful for the characterization of processing results. The processing variables considered were time and temperature for each of the processing steps of the double diffusion method, physical constants that influence the impurity distribution in silicon, and device dimensions. In evaluating the impurity atom distribution, the diffusion coefficient was assumed to be independent of impurity concentration and the superposition model was assumed for the interaction of the two oppositely charged impurities. In evaluating the electrical parameters, use of a one dimensional model and the modified Moll-Ross relations were assumed to be adequate in relating variations in electrical characteristics to variations in processing variables and physical properties.

  4. Forging of eccentric co-extruded Al-Mg compounds and analysis of the interface strength

    NASA Astrophysics Data System (ADS)

    Förster, W.; Binotsch, C.; Awiszus, B.; Lehmann, T.; Müller, J.; Kirbach, C.; Stockmann, M.; Ihlemann, J.

    2016-03-01

    Within the subproject B3 of the Collaborative Research Center 692 it has been shown that Al-Mg compounds with a good bonding quality can be produced by hydrostatic coextrusion. During processing by forging, the aluminum sleeve is thinned in areas of high strains depending on the component geometry. To solve this problem an eccentric core arrangement during co-extrusion was investigated. Based on the results of FE-simulations, the experimental validation is presented in this work. Rods with an offset of 0.25, 0.5 and 0.75 mm were produced by eccentric hydrostatic co-extrusion. Ultrasonic testing was used to evaluate the bonding quality across the entire rods. For the forging investigations the basic process Rising was chosen. The still good bonding quality after forging was examined by dye penetrant testing and optical microscopy. For an optimal stress transfer between the materials across the entire component, a sufficient bonding between the materials is essential. To evaluate the interface strength, a special bending test was developed. For the conception of the bending specimens it was required to analyze the Rising specimens geometry. These analyses were performed using a reconstruction of the geometrical data based on computer tomography (CT) investigations. The comparison with the numerically deter-mined Rising specimen geometry shows good correlation. Parametric Finite Element Analyses of the bending test were used to develop the load case and the specimen geometry. By means of iterative adaption of load application, bearing and specimen geometry parameters, an advantageous stress state and experimentally applicable configuration were found. Based on this conception, the experimental setup was configured and bending tests were performed. The interface strength was deter-mined by the calculation of the maximum interlaminar interfacial tension stress using the experimental interface failure force and the bending FE model.

  5. Analysis of the thermo-mechanical deformations in a hot forging tool by numerical simulation

    NASA Astrophysics Data System (ADS)

    L-Cancelos, R.; Varas, F.; Martín, E.; Viéitez, I.

    2016-03-01

    Although programs have been developed for the design of tools for hot forging, its design is still largely based on the experience of the tool maker. This obliges to build some test matrices and correct their errors to minimize distortions in the forged piece. This phase prior to mass production consumes time and material resources, which makes the final product more expensive. The forging tools are usually constituted by various parts made of different grades of steel, which in turn have different mechanical properties and therefore suffer different degrees of strain. Furthermore, the tools used in the hot forging are exposed to a thermal field that also induces strain or stress based on the degree of confinement of the piece. Therefore, the mechanical behaviour of the assembly is determined by the contact between the different pieces. The numerical simulation allows to analyse different configurations and anticipate possible defects before tool making, thus, reducing the costs of this preliminary phase. In order to improve the dimensional quality of the manufactured parts, the work presented here focuses on the application of a numerical model to a hot forging manufacturing process in order to predict the areas of the forging die subjected to large deformations. The thermo-mechanical model developed and implemented with free software (Code-Aster) includes the strains of thermal origin, strains during forge impact and contact effects. The numerical results are validated with experimental measurements in a tooling set that produces forged crankshafts for the automotive industry. The numerical results show good agreement with the experimental tests. Thereby, a very useful tool for the design of tooling sets for hot forging is achieved.

  6. Screw thread parameter measurement system based on image processing method

    NASA Astrophysics Data System (ADS)

    Rao, Zhimin; Huang, Kanggao; Mao, Jiandong; Zhang, Yaya; Zhang, Fan

    2013-08-01

    In the industrial production, as an important transmission part, the screw thread is applied extensively in many automation equipments. The traditional measurement methods of screw thread parameter, including integrated test methods of multiparameters and the single parameter measurement method, belong to contact measurement method. In practical the contact measurement exists some disadvantages, such as relatively high time cost, introducing easily human error and causing thread damage. In this paper, as a new kind of real-time and non-contact measurement method, a screw thread parameter measurement system based on image processing method is developed to accurately measure the outside diameter, inside diameter, pitch diameter, pitch, thread height and other parameters of screw thread. In the system the industrial camera is employed to acquire the image of screw thread, some image processing methods are used to obtain the image profile of screw thread and a mathematics model is established to compute the parameters. The C++Builder 6.0 is employed as the software development platform to realize the image process and computation of screw thread parameters. For verifying the feasibility of the measurement system, some experiments were carried out and the measurement errors were analyzed. The experiment results show the image measurement system satisfies the measurement requirements and suitable for real-time detection of screw thread parameters mentioned above. Comparing with the traditional methods the system based on image processing method has some advantages, such as, non-contact, easy operation, high measuring accuracy, no work piece damage, fast error analysis and so on. In the industrial production, this measurement system can provide an important reference value for development of similar parameter measurement system.

  7. Image processing method for multicore fiber geometric parameters

    NASA Astrophysics Data System (ADS)

    Zhang, Chuanbiao; Ning, Tigang; Li, Jing; Li, Chao; Ma, Shaoshuo

    2016-05-01

    An image processing method has been developed to obtain multicore fiber geometric parameters. According to the characteristics of multicore fiber, we using MATLAB to processing the sectional view of the multicore fiber (MCF), and the algorithm mainly concludes the following steps: filter out image noise, edge detection, use an appropriate threshold for boundary extraction and an improved curve-fitting algorithm for reconstruction the cross section, then we get the relative geometric parameters of the MCF in pixels. We also compares different edge detection operator and analyzes each detection results, which can provide a meaningful reference for edge detection.

  8. Computer simulation of the forging of fine grain IN-718 alloy

    NASA Astrophysics Data System (ADS)

    Srinivasan, R.; Ramnarayan, V.; Deshpande, U.; Jain, V.; Weiss, I.

    1993-09-01

    In recent years, there has been great emphasis on the use of computer-aided tools in process design. The key to the success of any computer modeling is the accurate knowledge of the mechanical and thermal properties of the various components of a manufacturing system. In order to develop a data base of forging properties of the nickel-base alloy IN-718, isothermal constant strain-rate compression tests were conducted on the annealed fine-grain material over the temperature range 871 °C to 1149 °C (1600 °F to 2100 °F) and strain-rate range 0. 001 to 10 s-1. Empirical relationships among flow stress, strain rate, and temperature developed based on these tests, along with experimentally measured heat-transfer and friction coefficients, were used in the program ALPID to simulate nonisothermal forging of “double-cone” specimens. The simulation results were compared with actual forging in an industrial forge press. The good agreement between simulation and forging results indicates that when a complete data base of materials properties is available, computer modeling can be used effectively to study the forging process.

  9. Computer simulation of the forging of fine grain IN-718 alloy

    SciTech Connect

    Srinivasan, R.; Deshpande, U.; Weiss, I. . Mechanical and Materials Engineering Dept.); Ramnarayan, V. ); Jain, V. . Mechanical and Aerospace Engineering Dept.)

    1993-09-01

    In recent years, there has been great emphasis on the use of computer-aided tools in process design. The key to the success of any computer modeling is the accurate knowledge of the mechanical and thermal properties of the various components of a manufacturing system. In order to develop a data base of forging properties of the nickel-base alloy IN-718, isothermal constant strain-rate compression tests were conducted on the annealed fine-grain material over the temperature range 871 C to 1,149 C (1,600 F to 2,100 F) and strain-rate range 0.001 to 10 s[sup [minus]1]. Empirical relationships among flow stress, strain rate, and temperature developed based on these tests, along with experimentally measured heat-transfer and friction coefficients, were used in the program ALPID to simulate nonisothermal forging of double-cone specimens. The simulation results were compared with actual forging in an industrial forge press. The good agreement between simulation and forging results indicates that when a complete data base of materials properties is available, computer modeling can be used effectively to study the forging process.

  10. Selecting forged aluminum for automotive applications

    SciTech Connect

    Holtz, M.A.; Davis, J.; Crawford, D.

    1984-01-01

    With the current and future efforts to downsize automobiles and reduce their weight, strong lightweight materials, in various product forms, are being substituted for many traditionally ferrous components. One of the substitute materials is aluminum, which although itself is not new to automobiles is finding novel applications as forgings in critical chassis and suspension areas. The 1984 Corvette provides an excellent example of how the use of forged aluminum can reduce unsprung and overall weight as well as improve performance without compromising the integrity of the vehicle. Using aluminum as forgings permits taking maximum advantage of its high strength-to-weight ratio, excellent ductility and toughness, and good corrosion resistance. This paper discusses the various considerations to be entertained when looking at aluminum forgings for automotive applications and the benefits of planning for these lightweight parts early in the design phase.

  11. The optimization of operating parameters on microalgae upscaling process planning.

    PubMed

    Ma, Yu-An; Huang, Hsin-Fu; Yu, Chung-Chyi

    2016-03-01

    The upscaling process planning developed in this study primarily involved optimizing operating parameters, i.e., dilution ratios, during process designs. Minimal variable cost was used as an indicator for selecting the optimal combination of dilution ratios. The upper and lower mean confidence intervals obtained from the actual cultured cell density data were used as the final cell density stability indicator after the operating parameters or dilution ratios were selected. The process planning method and results were demonstrated through three case studies of batch culture simulation. They are (1) final objective cell densities were adjusted, (2) high and low light intensities were used for intermediate-scale cultures, and (3) the number of culture days was expressed as integers for the intermediate-scale culture. PMID:26739144

  12. Stellar atmospheric parameter estimation using Gaussian process regression

    NASA Astrophysics Data System (ADS)

    Bu, Yude; Pan, Jingchang

    2015-02-01

    As is well known, it is necessary to derive stellar parameters from massive amounts of spectral data automatically and efficiently. However, in traditional automatic methods such as artificial neural networks (ANNs) and kernel regression (KR), it is often difficult to optimize the algorithm structure and determine the optimal algorithm parameters. Gaussian process regression (GPR) is a recently developed method that has been proven to be capable of overcoming these difficulties. Here we apply GPR to derive stellar atmospheric parameters from spectra. Through evaluating the performance of GPR on Sloan Digital Sky Survey (SDSS) spectra, Medium resolution Isaac Newton Telescope Library of Empirical Spectra (MILES) spectra, ELODIE spectra and the spectra of member stars of galactic globular clusters, we conclude that GPR can derive stellar parameters accurately and precisely, especially when we use data preprocessed with principal component analysis (PCA). We then compare the performance of GPR with that of several widely used regression methods (ANNs, support-vector regression and KR) and find that with GPR it is easier to optimize structures and parameters and more efficient and accurate to extract atmospheric parameters.

  13. Process Parameters Optimization in Single Point Incremental Forming

    NASA Astrophysics Data System (ADS)

    Gulati, Vishal; Aryal, Ashmin; Katyal, Puneet; Goswami, Amitesh

    2016-04-01

    This work aims to optimize the formability and surface roughness of parts formed by the single-point incremental forming process for an Aluminium-6063 alloy. The tests are based on Taguchi's L18 orthogonal array selected on the basis of DOF. The tests have been carried out on vertical machining center (DMC70V); using CAD/CAM software (SolidWorks V5/MasterCAM). Two levels of tool radius, three levels of sheet thickness, step size, tool rotational speed, feed rate and lubrication have been considered as the input process parameters. Wall angle and surface roughness have been considered process responses. The influential process parameters for the formability and surface roughness have been identified with the help of statistical tool (response table, main effect plot and ANOVA). The parameter that has the utmost influence on formability and surface roughness is lubrication. In the case of formability, lubrication followed by the tool rotational speed, feed rate, sheet thickness, step size and tool radius have the influence in descending order. Whereas in surface roughness, lubrication followed by feed rate, step size, tool radius, sheet thickness and tool rotational speed have the influence in descending order. The predicted optimal values for the wall angle and surface roughness are found to be 88.29° and 1.03225 µm. The confirmation experiments were conducted thrice and the value of wall angle and surface roughness were found to be 85.76° and 1.15 µm respectively.

  14. Compressed Air System Optimization Project Improves Production at a Metal Forging Plant (Modern Forge, TN, Plant)

    SciTech Connect

    2000-12-01

    In 1995, Modern Forge of Tennessee implemented a compressed air system improvement project at its Piney Flats, Tennessee, forging plant. Due to the project’s implementation, the plant was able to operate with fewer compressors and improve its product quality, thus allowing it to increase productivity. The project also resulted in considerable energy and maintenance savings.

  15. Analysis of dip coating processing parameters by double optical monitoring.

    PubMed

    Horowitz, Flavio; Michels, Alexandre F

    2008-05-01

    Double optical monitoring is applied to determine the influence of main process parameters on the formation of sulfated zirconia and self-assembled mesoporous silica solgel films by dip coating. In addition, we analyze, for the first time to the best of our knowledge, the influence of withdrawal speed, temperature, and relative humidity on refractive-index and physical thickness variations (uncertainties of +/-0.005 and +/-7 nm) during the process. Results provide insight into controlled production of single and multilayer films from complex fluids by dip coating. PMID:18449244

  16. Making randomised trials more efficient: report of the first meeting to discuss the Trial Forge platform.

    PubMed

    Treweek, Shaun; Altman, Doug G; Bower, Peter; Campbell, Marion; Chalmers, Iain; Cotton, Seonaidh; Craig, Peter; Crosby, David; Davidson, Peter; Devane, Declan; Duley, Lelia; Dunn, Janet; Elbourne, Diana; Farrell, Barbara; Gamble, Carrol; Gillies, Katie; Hood, Kerry; Lang, Trudie; Littleford, Roberta; Loudon, Kirsty; McDonald, Alison; McPherson, Gladys; Nelson, Annmarie; Norrie, John; Ramsay, Craig; Sandercock, Peter; Shanahan, Daniel R; Summerskill, William; Sydes, Matt; Williamson, Paula; Clarke, Mike

    2015-01-01

    Randomised trials are at the heart of evidence-based healthcare, but the methods and infrastructure for conducting these sometimes complex studies are largely evidence free. Trial Forge ( www.trialforge.org ) is an initiative that aims to increase the evidence base for trial decision making and, in doing so, to improve trial efficiency.This paper summarises a one-day workshop held in Edinburgh on 10 July 2014 to discuss Trial Forge and how to advance this initiative. We first outline the problem of inefficiency in randomised trials and go on to describe Trial Forge. We present participants' views on the processes in the life of a randomised trial that should be covered by Trial Forge.General support existed at the workshop for the Trial Forge approach to increase the evidence base for making randomised trial decisions and for improving trial efficiency. Agreed upon key processes included choosing the right research question; logistical planning for delivery, training of staff, recruitment, and retention; data management and dissemination; and close down. The process of linking to existing initiatives where possible was considered crucial. Trial Forge will not be a guideline or a checklist but a 'go to' website for research on randomised trials methods, with a linked programme of applied methodology research, coupled to an effective evidence-dissemination process. Moreover, it will support an informal network of interested trialists who meet virtually (online) and occasionally in person to build capacity and knowledge in the design and conduct of efficient randomised trials.Some of the resources invested in randomised trials are wasted because of limited evidence upon which to base many aspects of design, conduct, analysis, and reporting of clinical trials. Trial Forge will help to address this lack of evidence. PMID:26044814

  17. Diffusion parameters of indium for silicon process modeling

    NASA Astrophysics Data System (ADS)

    Kizilyalli, I. C.; Rich, T. L.; Stevie, F. A.; Rafferty, C. S.

    1996-11-01

    The diffusion parameters of indium in silicon are investigated. Systematic diffusion experiments in dry oxidizing ambients at temperatures ranging from 800 to 1050 °C are conducted using silicon wafers implanted with indium. Secondary-ion-mass spectrometry (SIMS) is used to analyze the dopant distribution before and after heat treatment. The oxidation-enhanced diffusion parameter [R. B. Fair, in Semiconductor Materials and Process Technology Handbook, edited by G. E. McGuire (Noyes, Park Ridge, NJ, 1988); A. M. R. Lin, D. A. Antoniadis, and R. W. Dutton, J. Electrochem. Soc. Solid-State Sci. Technol. 128, 1131 (1981); D. A. Antoniadis and I. Moskowitz, J. Appl. Phys. 53, 9214 (1982)] and the segregation coefficient at the Si/SiO2 interface [R. B. Fair and J. C. C. Tsai, J. Electrochem. Soc. Solid-State Sci. Technol. 125, 2050 (1978)] (ratio of indium concentration in silicon to that in silicon dioxide) are extracted as a function of temperature using SIMS depth profiles and the silicon process simulator PROPHET [M. Pinto, D. M. Boulin, C. S. Rafferty, R. K. Smith, W. M. Coughran, I. C. Kizilyalli, and M. J. Thoma, in IEDM Technical Digest, 1992, p. 923]. It is observed that the segregation coefficient of indium at the Si/SiO2 interface is mIn≪1, similar to boron; however, unlike boron, the segregation coefficient of indium at the Si/SiO2 interface decreases with increasing temperature. Extraction results are summarized in analytical forms suitable for incorporation into other silicon process simulators. Finally, the validity of the extracted parameters is verified by comparing the simulated and measured SIMS profiles for an indium implanted buried-channel p-channel metal-oxide-semiconductor field-effect-transistor [I. C. Kizilyalli, F. A. Stevie, and J. D. Bude, IEEE Electron Device Lett. (1996)] process that involves a gate oxidation and various other thermal processes.

  18. Parameters in selective laser melting for processing metallic powders

    NASA Astrophysics Data System (ADS)

    Kurzynowski, Tomasz; Chlebus, Edward; Kuźnicka, Bogumiła; Reiner, Jacek

    2012-03-01

    The paper presents results of studies on Selective Laser Melting. SLM is an additive manufacturing technology which may be used to process almost all metallic materials in the form of powder. Types of energy emission sources, mainly fiber lasers and/or Nd:YAG laser with similar characteristics and the wavelength of 1,06 - 1,08 microns, are provided primarily for processing metallic powder materials with high absorption of laser radiation. The paper presents results of selected variable parameters (laser power, scanning time, scanning strategy) and fixed parameters such as the protective atmosphere (argon, nitrogen, helium), temperature, type and shape of the powder material. The thematic scope is very broad, so the work was focused on optimizing the process of selective laser micrometallurgy for producing fully dense parts. The density is closely linked with other two conditions: discontinuity of the microstructure (microcracks) and stability (repeatability) of the process. Materials used for the research were stainless steel 316L (AISI), tool steel H13 (AISI), and titanium alloy Ti6Al7Nb (ISO 5832-11). Studies were performed with a scanning electron microscope, a light microscopes, a confocal microscope and a μCT scanner.

  19. West Flank Coso, CA FORGE Magnetotelluric Inversion

    DOE Data Explorer

    Doug Blankenship

    2016-05-16

    The Coso Magnetotelluric (MT) dataset of which the West Flank FORGE MT data is a subset, was collected by Schlumberger / WesternGeco and initially processed by the WesternGeco GeoSolutions Integrated EM Center of Excellence in Milan, Italy. The 2011 data was based on 99 soundings that were centered on the West Flank geothermal prospect. The new soundings along with previous data from 2003 and 2006 were incorporated into a 3D inversion. Full impedance tensor data were inverted in the 1-3000 Hz range. The modelling report notes several noise sources, specifically the DC powerline that is 20,000 feet west of the survey area, and may have affected data in the 0.02 to 10 Hz range. Model cell dimensions of 450 x 450 x 65 feet were used to avoid computational instability in the 3D model. The fit between calculated and observed MT values for the final model run had an RMS value of 1.807. The included figure from the WesternGeco report shows the sounding locations from the 2011, 2006 and 2003 surveys.

  20. Thermo-Mechanical Processing Parameters for the INCONEL ALLOY 740

    SciTech Connect

    Ludtka, G.M.; Smith, G.

    2007-11-19

    In 2000, a Cooperative Research and Development Agreement (CRADA) was undertaken between the Oak Ridge National Laboratory (ORNL) and the Special Metals Corporation (SMC) to determine the mechanical property response of the IN740 alloy to help establish thermo-mechanical processing parameters for the use of this alloy in supercritical and ultra-critical boiler tubes with the potential for other end uses. SMC had developed an alloy, commercially known as INCONEL alloy 740, which exhibited various beneficial physical, mechanical, and chemical properties. As part of SMC's on-going efforts to optimize this alloy for targeted boiler applications there was a need to develop an understanding of the thermo-mechanical response of the material, characterize the resulting microstructure from this processing, and possibly, utilize models to develop the appropriate processing scheme for this product.

  1. Quality of margarine: fats selection and processing parameters.

    PubMed

    Miskandar, Mat Sahri; Man, Yaakob Che; Yusoff, Mohd Suria Affandi; Rahman, Russly Abd

    2005-01-01

    Optimum processing conditions on palm oil-based formulations are required to produce the desired quality margarine. As oils and fats contribute to the overall property of the margarine, this paper will review the importance of beta' tending oils and fats in margarine formulation, effects of the processing parameters -- emulsion temperature, flow-rate, product temperature and pin-worker speed -- on palm oil margarines produced and their subsequent behaviour in storage. Palm oil, which contributes the beta' crystal polymorph and the best alternative to hydrogenated liquid fats, and the processing conditions can affect the margarine consistency by influencing the solid fat content (SFC) and the types of crystal polymorph formed during production as well as in storage. Palm oil, or hydrogenated palm oil and olein, in mixture with oils of beta tending, can veer the product to the beta' crystal form. However, merely having beta' crystal tending oils is not sufficient as the processing conditions are also important. The emulsion temperature had no significant effect on the consistency and polymorphic changes of the product during storage, even though differences were observed during processing. The consistency of margarine during storage was high at low emulsion flow-rates and low at high flow rates. The temperature of the scraped-surface tube-cooler is the most important parameter in margarine processing. High temperature will produce a hardened product with formation of beta-crystals during storage. The speed of the pin-worker is responsible for inducing crystallization but, at the same time, destroys the crystal agglomerates, resulting in melting. PMID:16326646

  2. Estimating demographic parameters using hidden process dynamic models.

    PubMed

    Gimenez, Olivier; Lebreton, Jean-Dominique; Gaillard, Jean-Michel; Choquet, Rémi; Pradel, Roger

    2012-12-01

    Structured population models are widely used in plant and animal demographic studies to assess population dynamics. In matrix population models, populations are described with discrete classes of individuals (age, life history stage or size). To calibrate these models, longitudinal data are collected at the individual level to estimate demographic parameters. However, several sources of uncertainty can complicate parameter estimation, such as imperfect detection of individuals inherent to monitoring in the wild and uncertainty in assigning a state to an individual. Here, we show how recent statistical models can help overcome these issues. We focus on hidden process models that run two time series in parallel, one capturing the dynamics of the true states and the other consisting of observations arising from these underlying possibly unknown states. In a first case study, we illustrate hidden Markov models with an example of how to accommodate state uncertainty using Frequentist theory and maximum likelihood estimation. In a second case study, we illustrate state-space models with an example of how to estimate lifetime reproductive success despite imperfect detection, using a Bayesian framework and Markov Chain Monte Carlo simulation. Hidden process models are a promising tool as they allow population biologists to cope with process variation while simultaneously accounting for observation error. PMID:22373775

  3. Unraveling the Processing Parameters in Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    Schneider, Judy; Nunes, Arthur C., Jr.

    2005-01-01

    In friction stir welding (FSW), a rotating threaded pin tool is translated along a weld seam, literally stirring the edges of the seam together. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path or paths is required. In this study, various markers are used to trace the flow paths of the metal. X-ray radiographs record the segmentation and position of the wire. Several variations in the trajectories can be differentiated within the weld zone.

  4. Correlations of Melt Pool Geometry and Process Parameters During Laser Metal Deposition by Coaxial Process Monitoring

    NASA Astrophysics Data System (ADS)

    Ocylok, Sörn; Alexeev, Eugen; Mann, Stefan; Weisheit, Andreas; Wissenbach, Konrad; Kelbassa, Ingomar

    One major demand of today's laser metal deposition (LMD) processes is to achieve a fail-save build-up regarding changing conditions like heat accumulations. Especially for the repair of thin parts like turbine blades is the knowledge about the correlations between melt pool behavior and process parameters like laser power, feed rate and powder mass stream indispensable. The paper will show the process layout with the camera based coaxial monitoring system and the quantitative influence of the process parameters on the melt pool geometry. Therefore the diameter, length and area of the melt pool are measured by a video analytic system at various parameters and compared with the track wide in cross-sections and the laser spot diameter. The influence of changing process conditions on the melt pool is also investigated. On the base of these results an enhanced process of the build-up of a multilayer one track fillet geometry will be presented.

  5. 4. FORGE, ANVIL, PEDESTAL GRINDER, AND BELT DRIVES. NOTE WATERWHEEL ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    4. FORGE, ANVIL, PEDESTAL GRINDER, AND BELT DRIVES. NOTE WATERWHEEL NEEDLE VALVE CASTING HANGING ON THE WALL ABOVE THE FORGE. VIEW TO NORTH. - Santa Ana River Hydroelectric System, SAR-1 Machine Shop, Redlands, San Bernardino County, CA

  6. Stainless-steel elbows formed by spin forging

    NASA Technical Reports Server (NTRS)

    1964-01-01

    Large seamless austenitic stainless steel elbows are fabricated by spin forging /rotary shear forming/. A specially designed spin forging tool for mounting on a hydrospin machine has been built for this purpose.

  7. 1. MIDDLE FORGE DISPLAY, ACROSS FROM BUILDING NO. 114 on ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    1. MIDDLE FORGE DISPLAY, ACROSS FROM BUILDING NO. 114 on FARLEY AVE. MARKER ON DISPLAY ITSELF READS: FORGE AND TOOLS, USED AT MIDDLE FORGE LOCATED AT PICATINNY LAKE OUTLETS 1749 TO 1880. NEARBY MARKER READS: THE MIDDLE FORGE. THE MT. HOPE IRONWORKS INCLUDING A TRACT CALLED THE MIDDLE FORGE, SUPPLIED ORDNANCE MATERIAL TO THE CONTINENTAL ARMY IN THE AMERICAN REVOLUTION. GENERAL WASHINGTON INSPECTED THE FACILITY. THE WAR DEPARTMENT PURCHASED THE MIDDLE FORGE PORPERTY FOR AN ARMY POWDER DEPOT IN 1879-80. THE FORGE AND TOOLS WERE RECOVERED AT THE ACTUAL SITE NEAR PICATINNY PEAK. THROUGH THE YEARS, THE MIDDLE FORGE DISPLAY CAME TO BE THE UNOFFICIAL SYMBOL OF PICATINNY ARSENAL. -- HISTORICAL OFFICE NO DATE - Picatinny Arsenal, State Route 15 near I-80, Dover, Morris County, NJ

  8. Characteristics, Process Parameters, and Inner Components of Anaerobic Bioreactors

    PubMed Central

    Abdelgadir, Awad; Chen, Xiaoguang; Liu, Jianshe; Xie, Xuehui; Zhang, Jian; Zhang, Kai; Wang, Heng; Liu, Na

    2014-01-01

    The anaerobic bioreactor applies the principles of biotechnology and microbiology, and nowadays it has been used widely in the wastewater treatment plants due to their high efficiency, low energy use, and green energy generation. Advantages and disadvantages of anaerobic process were shown, and three main characteristics of anaerobic bioreactor (AB), namely, inhomogeneous system, time instability, and space instability were also discussed in this work. For high efficiency of wastewater treatment, the process parameters of anaerobic digestion, such as temperature, pH, Hydraulic retention time (HRT), Organic Loading Rate (OLR), and sludge retention time (SRT) were introduced to take into account the optimum conditions for living, growth, and multiplication of bacteria. The inner components, which can improve SRT, and even enhance mass transfer, were also explained and have been divided into transverse inner components, longitudinal inner components, and biofilm-packing material. At last, the newly developed special inner components were discussed and found more efficient and productive. PMID:24672798

  9. Characteristics, process parameters, and inner components of anaerobic bioreactors.

    PubMed

    Abdelgadir, Awad; Chen, Xiaoguang; Liu, Jianshe; Xie, Xuehui; Zhang, Jian; Zhang, Kai; Wang, Heng; Liu, Na

    2014-01-01

    The anaerobic bioreactor applies the principles of biotechnology and microbiology, and nowadays it has been used widely in the wastewater treatment plants due to their high efficiency, low energy use, and green energy generation. Advantages and disadvantages of anaerobic process were shown, and three main characteristics of anaerobic bioreactor (AB), namely, inhomogeneous system, time instability, and space instability were also discussed in this work. For high efficiency of wastewater treatment, the process parameters of anaerobic digestion, such as temperature, pH, Hydraulic retention time (HRT), Organic Loading Rate (OLR), and sludge retention time (SRT) were introduced to take into account the optimum conditions for living, growth, and multiplication of bacteria. The inner components, which can improve SRT, and even enhance mass transfer, were also explained and have been divided into transverse inner components, longitudinal inner components, and biofilm-packing material. At last, the newly developed special inner components were discussed and found more efficient and productive. PMID:24672798

  10. [A method of temperature measurement for hot forging with surface oxide based on infrared spectroscopy].

    PubMed

    Zhang, Yu-cun; Qi, Yan-de; Fu, Xian-bin

    2012-05-01

    High temperature large forging is covered with a thick oxide during forging. It leads to a big measurement data error. In this paper, a method of measuring temperature based on infrared spectroscopy is presented. It can effectively eliminate the influence of surface oxide on the measurement of temperature. The method can measure the surface temperature and emissivity of the oxide directly using the infrared spectrum. The infrared spectrum is radiated from surface oxide of forging. Then it can derive the real temperature of hot forging covered with the oxide using the heat exchange equation. In order to greatly restrain interference spectroscopy through included in the received infrared radiation spectrum, three interference filter system was proposed, and a group of optimal gap parameter values using spectral simulation were obtained. The precision of temperature measurement was improved. The experimental results show that the method can accurately measure the surface temperature of high temperature forging covered with oxide. It meets the requirements of measurement accuracy, and the temperature measurement method is feasible according to the experiment result. PMID:22827063

  11. Optimization of polyetherimide processing parameters for optical interconnect applications

    NASA Astrophysics Data System (ADS)

    Zhao, Wei; Johnson, Peter; Wall, Christopher

    2015-10-01

    ULTEM® polyetherimide (PEI) resins have been used in opto-electronic markets since the optical properties of these materials enable the design of critical components under tight tolerances. PEI resins are the material of choice for injection molded integrated lens applications due to good dimensional stability, near infrared (IR) optical transparency, low moisture uptake and high heat performance. In most applications, parts must be produced consistently with minimal deviations to insure compatibility throughout the lifetime of the part. With the large number of lenses needed for this market, injection molding has been optimized to maximize the production rate. These optimized parameters for high throughput may or may not translate to an optimized optical performance. In this paper, we evaluate and optimize PEI injection molding processes with a focus on optical property performance. A commonly used commercial grade was studied to determine factors and conditions which contribute to optical transparency, color, and birefringence. Melt temperature, mold temperature, injection speed and cycle time were varied to develop optimization trials and evaluate optical properties. These parameters could be optimized to reduce in-plane birefringence from 0.0148 to 0.0006 in this study. In addition, we have studied an optically smooth, sub-10nm roughness mold to re-evaluate material properties with minimal influence from mold quality and further refine resin and process effects for the best optical performance.

  12. Impact of Temperature on Cooling Structural Variation of Forging Dies

    NASA Astrophysics Data System (ADS)

    Piesova, Marianna; Czan, Andrej

    2014-12-01

    The article is focused on the issue of die forging in the automotive industry. The cooling effect of temperature on the structure of forged die are under review. In the article, there is elaborated the analysis of theoretical knowledge in the field, focusing on die forging and experimentally proven effect of the cooling rate on the final structure of forged dies made of hypoeutectic carbon steel C56E2.

  13. Achieving Fine Beta Grain Structure in a Metastable Beta Titanium Alloy Through Multiple Forging-Annealing Cycles

    NASA Astrophysics Data System (ADS)

    Zafari, Ahmad; Ding, Yunpeng; Cui, Jianzhong; Xia, Kenong

    2016-04-01

    A coarse-grained (order of 1 mm) Ti-5553 metastable beta alloy was subjected to multiple passes of low-temperature forging and multiple forging plus annealing cycles, respectively. In the forging only processing, strain was concentrated in the shear bands formed and accumulated with each forging pass, resulting in a heterogeneous microstructure and eventual cracking along the shear bands. In contrast, the introduction of a short beta annealing after each forging step led to fine recrystallized grains (50 to 100 µm) formed in the shear bands, and a uniformly refined beta grain structure after four cycles. This is attributed to the strengthening effect of the fine grains, causing redistribution of most severe strains to the coarse grain region in the subsequent forging, consistent with the simulated results by finite element analysis. The analyses of the microstructures and simulated strain distributions revealed that the critical strain for recrystallization is between 0.2 and 0.5 and the strain to fracture to be ~0.8 to 0.9. The fine-grained (50 to 100 µm) beta alloy, however, fractured at a much smaller strain of <0.4 during the next forging step, owing to the formation of stress-induced martensitic α″ which is more prevalent in fine grains than in coarse ones.

  14. Achieving Fine Beta Grain Structure in a Metastable Beta Titanium Alloy Through Multiple Forging-Annealing Cycles

    NASA Astrophysics Data System (ADS)

    Zafari, Ahmad; Ding, Yunpeng; Cui, Jianzhong; Xia, Kenong

    2016-07-01

    A coarse-grained (order of 1 mm) Ti-5553 metastable beta alloy was subjected to multiple passes of low-temperature forging and multiple forging plus annealing cycles, respectively. In the forging only processing, strain was concentrated in the shear bands formed and accumulated with each forging pass, resulting in a heterogeneous microstructure and eventual cracking along the shear bands. In contrast, the introduction of a short beta annealing after each forging step led to fine recrystallized grains (50 to 100 µm) formed in the shear bands, and a uniformly refined beta grain structure after four cycles. This is attributed to the strengthening effect of the fine grains, causing redistribution of most severe strains to the coarse grain region in the subsequent forging, consistent with the simulated results by finite element analysis. The analyses of the microstructures and simulated strain distributions revealed that the critical strain for recrystallization is between 0.2 and 0.5 and the strain to fracture to be ~0.8 to 0.9. The fine-grained (50 to 100 µm) beta alloy, however, fractured at a much smaller strain of <0.4 during the next forging step, owing to the formation of stress-induced martensitic α″ which is more prevalent in fine grains than in coarse ones.

  15. Predicting parameters of degradation succession processes of Tibetan Kobresia grasslands

    NASA Astrophysics Data System (ADS)

    Lin, L.; Li, Y. K.; Xu, X. L.; Zhang, F. W.; Du, Y. G.; Liu, S. L.; Guo, X. W.; Cao, G. M.

    2015-08-01

    In the past two decades, increasing human activity (i.e., overgrazing) in the Tibetan Plateau has strongly influenced plant succession processes, resulting in the degradation of alpine grasslands. Therefore, it is necessary to diagnose the degree of degradation to enable implementation of appropriate management for sustainable exploitation and protection of alpine grasslands. Here, we investigated environmental factors and plant functional group quantity factors (PFGs) during the alpine grassland succession processes. Principal component analysis (PCA) was used to identify the parameters indicative of degradation. We divided the entire degradation process into six stages. PFG types shifted from rhizome bunch grasses to rhizome plexus and dense plexus grasses during the degradation process. Leguminosae and Gramineae plants were replaced by Sedges during the advanced stages of degradation. The PFGs were classified into two reaction groups: the grazing-sensitive group, containing Kobresia humilis Mey, and Gramineae and Leguminosae plants, and the grazing-insensitive group, containing Kobresia pygmaea Clarke. The first group was correlated with live root biomass in the surface soil (0-10 cm), whereas the second group was strongly correlated with mattic epipedon thickness and K. pygmaea characteristics. The degree of degradation of alpine meadows may be delineated by development of mattic epipedon and PFG composition. Thus, meadows could be easily graded and their use adjusted based on our scaling system, which would help prevent irreversible degradation of important grasslands. Because relatively few environmental factors are investigated, this approach can save time and labor to formulate a conservation management plan for degraded alpine meadows.

  16. Predicting parameters of degradation succession processes of Tibetan Kobresia grasslands

    NASA Astrophysics Data System (ADS)

    Lin, L.; Li, Y. K.; Xu, X. L.; Zhang, F. W.; Du, Y. G.; Liu, S. L.; Guo, X. W.; Cao, G. M.

    2015-11-01

    In the past two decades, increasing human activity (i.e., overgrazing) in the Tibetan Plateau has strongly influenced plant succession processes, resulting in the degradation of alpine grasslands. Therefore, it is necessary to diagnose the degree of degradation to enable implementation of appropriate management for sustainable exploitation and protection of alpine grasslands. Here, we investigated environmental factors and plant functional group (PFG) quantity factors during the alpine grassland succession processes. Principal component analysis (PCA) was used to identify the parameters indicative of degradation. We divided the entire degradation process into six stages. PFG types shifted from rhizome bunchgrasses to rhizome plexus and dense-plexus grasses during the degradation process. Leguminosae and Gramineae plants were replaced by sedges during the advanced stages of degradation. The PFGs were classified into two reaction groups: the grazing-sensitive group, containing Kobresia humilis Mey, and Gramineae and Leguminosae plants, and the grazing-insensitive group, containing Kobresia pygmaea Clarke. The first group was correlated with live root biomass in the surface soil (0-10 cm), whereas the second group was strongly correlated with mattic epipedon thickness and K. pygmaea characteristics. The degree of degradation of alpine meadows may be delineated by development of mattic epipedon and PFG composition. Thus, meadows could be easily graded and their use adjusted based on our scaling system, which would help prevent irreversible degradation of important grasslands. Because relatively few environmental factors are investigated, this approach can save time and labor to formulate a conservation management plan for degraded alpine meadows.

  17. 22 CFR 121.10 - Forgings, castings, and machined bodies.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 22 Foreign Relations 1 2014-04-01 2014-04-01 false Forgings, castings, and machined bodies. 121.10... STATES MUNITIONS LIST Enumeration of Articles § 121.10 Forgings, castings, and machined bodies. The U.S. Munitions List controls as defense articles those forgings, castings, and other unfinished products, such...

  18. Co-Operative Training in the Sheffield Forging Industry

    ERIC Educational Resources Information Center

    Duncan, R.

    2008-01-01

    Purpose: The purpose of this paper is to give details of an operation carried out in Sheffield to increase the recruitment of young men into the steel forging industry. Design/methodology/approach: The Sheffield Forges Co-operative Training Scheme was designed to encourage boys to enter the forging industry and to provide them with training and…

  19. Analysis Of Potentiometric Methods Used For Crack Detection In Forging Tools

    NASA Astrophysics Data System (ADS)

    Pilc, Jozef; Drbúl, Mário; Stančeková, Dana; Varga, Daniel; Martinček, Juraj; Kuždák, Viktor

    2015-12-01

    Increased use of forging tools in mass production causes their increased wear and creates pressure to design more efficient renovation process. Renovation is complicated because of the identification of cracks expanding from the surface to the core material. Given that the production of forging tools is expensive, caused by the cost of tool steels and the thermo-chemical treatment, it is important to design forging tool with its easy renovation in mind. It is important to choose the right renovation technology, which will be able to restore the instrument to its original state while maintaining financial rentability. Choosing the right technology is difficult because of nitrided and heat-treated surface for high hardness and wear resistance. Article discusses the use of non-destructive method of detecting cracks taking into account the size of the cracks formed during working process.

  20. Exploring control parameters of two photon processes in solutions#

    PubMed Central

    GOSWAMI, DEBABRATA; NAG, AMIT

    2013-01-01

    Two-photon microscopy depends extensively on the two-photon absorption cross-sections of biologically relevant chromophores. High repetition rate (HRR) lasers are essential in multiphoton microscopy for generating satisfactory signal to noise at low average powers. However, HRR lasers generate thermal distortions in samples even with the slightest single photon absorption. We use an optical chopper with HRR lasers to intermittently ‘blank’ irradiation and effectively minimize thermal effects to result in a femtosecond z-scan setup that precisely measures the two-photon absorption (TPA) cross-sections of chromophores. Though several experimental factors impact such TPA measurements, a systematic effort to modulate and influence TPA characteristics is yet to evolve. Here, we present the effect of several control parameters on the TPA process that are independent of chromophore characteristics for femtosecond laser pulse based measurements; and demonstrate how the femtosecond laser pulse repetition rate, chromophore environment and incident laser polarization can become effective control parameters for such nonlinear optical properties. PMID:24098068

  1. Distributed parameter approach to the dynamics of complex biological processes

    SciTech Connect

    Lee, T.T.; Wang, F.Y.; Newell, R.B.

    1999-10-01

    Modeling and simulation of a complex biological process for the removal of nutrients (nitrogen and phosphorus) from municipal wastewater are addressed. The model developed in this work employs a distributed-parameter approach to describe the behavior of components within three different bioreaction zones and the behavior of sludge in the anaerobic zone and soluble phosphate in the aerobic zone in two experiments. Good results are achieved despite the apparent plant-model mismatch, such as uncertainties with the behavior of phosphorus-accumulating organisms. Validation of the proposed secondary-settler model shows that it is superior to two state-of-the-art models in terms of the sum of the square relative errors.

  2. Forging Inclusive Solutions: Experiential Earth Charter Education

    ERIC Educational Resources Information Center

    Hill, Linda D.

    2010-01-01

    Forging Inclusive Solutions describes the aims, methodology and outcomes of Inclusive Leadership Adventures, an experiential education curriculum for exploring the Earth Charter. Experiential education builds meaningful relationships, skills, awareness and an inclusive community based on the Earth Charter principles. When we meet people where they…

  3. Effect of processing parameters on the corrosion behaviour of friction stir processed AA 2219 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Surekha, K.; Murty, B. S.; Prasad Rao, K.

    2009-04-01

    The effect of processing parameters (rotation speed and traverse speed) on the corrosion behaviour of friction stir processed high strength precipitation hardenable AA 2219-T87 alloy was investigated. The results indicate that the rotation speed has a major influence in determining the rate of corrosion, which is attributed to the breaking down and dissolution of the intermetallic particles. Corrosion resistance of friction stir processed alloy was studied by potentiodynamic polarization, electrochemical impedance spectroscopy, salt spray and immersion tests.

  4. Analysis of forging limit for sintered porous metals

    SciTech Connect

    Han, H.N.; Oh, K.H.; Lee, D.N.

    1995-06-15

    Forging of sintered porous metals has been developed as a method for producing machine parts with good mechanical properties. To extend this manufacturing method to a wide range of applications, it will be helpful to have an understanding of the deformation, density change and fracture of sintered porous metals during forging. Especially, in order to avoid the possibility of surface fracture in forging of porous metals, it is necessary to know the forging limits of sintered porous metals. The purpose of this work is to calculate the forging limit curves of sintered porous metals using the various yield functions for porous metals.

  5. Optimisation of shock absorber process parameters using failure mode and effect analysis and genetic algorithm

    NASA Astrophysics Data System (ADS)

    Mariajayaprakash, Arokiasamy; Senthilvelan, Thiyagarajan; Vivekananthan, Krishnapillai Ponnambal

    2013-07-01

    The various process parameters affecting the quality characteristics of the shock absorber during the process were identified using the Ishikawa diagram and by failure mode and effect analysis. The identified process parameters are welding process parameters (squeeze, heat control, wheel speed, and air pressure), damper sealing process parameters (load, hydraulic pressure, air pressure, and fixture height), washing process parameters (total alkalinity, temperature, pH value of rinsing water, and timing), and painting process parameters (flowability, coating thickness, pointage, and temperature). In this paper, the process parameters, namely, painting and washing process parameters, are optimized by Taguchi method. Though the defects are reasonably minimized by Taguchi method, in order to achieve zero defects during the processes, genetic algorithm technique is applied on the optimized parameters obtained by Taguchi method.

  6. Effect of isothermal forging on microstructure and fatigue behavior of blended elemental Ti-6Al-4V powder compacts

    NASA Astrophysics Data System (ADS)

    Weiss, I.; Eylon, D.; Toaz, M. W.; Froes, F. H.

    1986-03-01

    The effect of isothermal hot forging (IHF) on microstructure, pore closure, and tensile and fatigue properties of Ti-6A1-4V blended elemental cold pressed and sintered powder compacts was investigated. Two types of sponge fines were used: (a) high chloride produced by the Hunter sodium reduction process (HP) and (b) low chloride produced by the electrolytic process (EP). The as-sintered HP compacts were 99 pct dense while the EP compacts were only 92 pct dense. All sintered preforms were isothermally hot forged below the beta transus temperature and reached almost full density. The microstructure of the HP forged compacts consisted of fine equiaxed alpha, while the EP forged compacts exhibited a coarse lenticular alpha structure after 30 pct reduction and a partially recrystallized structure after 68 pct reduction. It was found that EP compacts forged to a 30 pct reduction exhibited a low fatigue limit of 172 MPa (25 ksi), since the lenticular alpha morphology and the residual porosity resulted in premature fatigue crack initiation. On the other hand, a higher fatigue strength of 485 MPa (70 ksi) was obtained for EP compacts forged to a 78 pct reduction due to the mixed equiaxed/lenticular alpha morphology as well as removal of stress concentration features such as interparticle pore interfaces.

  7. Effects of process parameters in plastic, metal, and ceramic injection molding processes

    NASA Astrophysics Data System (ADS)

    Lee, Shi W.; Ahn, Seokyoung; Whang, Chul Jin; Park, Seong Jin; Atre, Sundar V.; Kim, Jookwon; German, Randall M.

    2011-09-01

    Plastic injection molding has been widely used in the past and is a dominant forming approach today. As the customer demands require materials with better engineering properties that were not feasible with polymers, powder injection molding with metal and ceramic powders has received considerable attention in recent decades. To better understand the differences in the plastic injection molding, metal injection molding, and ceramic injection molding, the effects of the core process parameters on the process performances has been studied using the state-of-the-art computer-aided engineering (CAE) design tool, PIMSolver® The design of experiments has been conducted using the Taguchi method to obtain the relative contributions of various process parameters onto the successful operations.

  8. Technical bases for precipitate hydrolysis process operating parameters

    SciTech Connect

    Bannochie, C.J.

    1992-10-05

    This report provides the experimental data and rationale in support of the operating parameters for precipitate hydrolysis specified in WSRC-RP-92737. The report is divided into two sections, the first dealing with lab-scale precipitate hydrolysis experimentation while the second part addresses large-scale runs conducted to demonstrate the revised operating parameters in the Precipitate Hydrolysis Experimental Facility (PHEF).

  9. Optimized process parameters for fabricating metal particles reinforced 5083 Al composite by friction stir processing

    PubMed Central

    Bauri, Ranjit; Yadav, Devinder; Shyam Kumar, C.N.; Janaki Ram, G.D.

    2015-01-01

    Metal matrix composites (MMCs) exhibit improved strength but suffer from low ductility. Metal particles reinforcement can be an alternative to retain the ductility in MMCs (Bauri and Yadav, 2010; Thakur and Gupta, 2007) [1,2]. However, processing such composites by conventional routes is difficult. The data presented here relates to friction stir processing (FSP) that was used to process metal particles reinforced aluminum matrix composites. The data is the processing parameters, rotation and traverse speeds, which were optimized to incorporate Ni particles. A wide range of parameters covering tool rotation speeds from 1000 rpm to 1800 rpm and a range of traverse speeds from 6 mm/min to 24 mm/min were explored in order to get a defect free stir zone and uniform distribution of particles. The right combination of rotation and traverse speed was found from these experiments. Both as-received coarse particles (70 μm) and ball-milled finer particles (10 μm) were incorporated in the Al matrix using the optimized parameters. PMID:26566541

  10. Optimized process parameters for fabricating metal particles reinforced 5083 Al composite by friction stir processing.

    PubMed

    Bauri, Ranjit; Yadav, Devinder; Shyam Kumar, C N; Janaki Ram, G D

    2015-12-01

    Metal matrix composites (MMCs) exhibit improved strength but suffer from low ductility. Metal particles reinforcement can be an alternative to retain the ductility in MMCs (Bauri and Yadav, 2010; Thakur and Gupta, 2007) [1,2]. However, processing such composites by conventional routes is difficult. The data presented here relates to friction stir processing (FSP) that was used to process metal particles reinforced aluminum matrix composites. The data is the processing parameters, rotation and traverse speeds, which were optimized to incorporate Ni particles. A wide range of parameters covering tool rotation speeds from 1000 rpm to 1800 rpm and a range of traverse speeds from 6 mm/min to 24 mm/min were explored in order to get a defect free stir zone and uniform distribution of particles. The right combination of rotation and traverse speed was found from these experiments. Both as-received coarse particles (70 μm) and ball-milled finer particles (10 μm) were incorporated in the Al matrix using the optimized parameters. PMID:26566541

  11. Technical bases for precipitate hydrolysis process operating parameters

    SciTech Connect

    Bannochie, C.J.; Lambert, D.P.

    1992-11-09

    This report provides the experimental data and rationale in support of the operating parameters for tetraphenylborate precipitate hydrolysis specified in WSRC-RP-92-737. The report is divided into two sections, the first dealing with lab-scale precipitate hydrolysis experimentation while the second part addresses large-scale runs conducted to demonstrate the revised operating parameters in the Precipitate Hydrolysis Experimental Facility (PHEF). The program was in conjunction with reducing the nitrite ion level in DWPF feed.

  12. Technical bases for precipitate hydrolysis process operating parameters. Revision 1

    SciTech Connect

    Bannochie, C.J.; Lambert, D.P.

    1992-11-09

    This report provides the experimental data and rationale in support of the operating parameters for tetraphenylborate precipitate hydrolysis specified in WSRC-RP-92-737. The report is divided into two sections, the first dealing with lab-scale precipitate hydrolysis experimentation while the second part addresses large-scale runs conducted to demonstrate the revised operating parameters in the Precipitate Hydrolysis Experimental Facility (PHEF). The program was in conjunction with reducing the nitrite ion level in DWPF feed.

  13. Influence of Process Parameter on Grit Blasting as a Pretreatment Process for Thermal Spraying

    NASA Astrophysics Data System (ADS)

    Bobzin, K.; Öte, M.; Linke, T. F.; Sommer, J.; Liao, X.

    2016-01-01

    In thermal spraying, uncoated substrates usually require roughening. As the most common roughening method, grit blasting increases the surface area and produces undercuts in almost all cases, which facilitate mechanical interlocking and thus promote the bonding between the substrate and coating. The effects of grit blasting parameters, i.e., the particle size, the blasting angle, the stand-off distance, and the pressure, on the resulting surface topography are investigated. Furthermore, the efficiency and wear behavior of the blasting media are analyzed. Influences of three different blasting media, corundum, alumina zirconia, and steel shot, on the surface roughening, are compared. By varying adjusted blasting parameters, different initial conditions (surface topography) are created. Subsequently, the substrate is coated, and the coating bond strength is measured. One of the main results of this publication is that alumina zirconia and steel grit show a longer lifetime than pure alumina as a blasting media. Moreover, it has been shown that the blasting parameters such as grain size, working pressure, and history (wear status) of the abrasive particles have a significant effect on the resulting surface topography. Additionally, systematical analysis in this study shows that the blasting parameters such as stand-off distance and blasting angle have a small influence on the results of the blasting process. Another important conclusion of this study is that the conventional surface parameters that have been analyzed in this study did not turn out to be suitable for describing the relationship between the surface topography of the substrate and resulting bond strength.

  14. Optimizing noise control strategy in a forging workshop.

    PubMed

    Razavi, Hamideh; Ramazanifar, Ehsan; Bagherzadeh, Jalal

    2014-01-01

    In this paper, a computer program based on a genetic algorithm is developed to find an economic solution for noise control in a forging workshop. Initially, input data, including characteristics of sound sources, human exposure, abatement techniques, and production plans are inserted into the model. Using sound pressure levels at working locations, the operators who are at higher risk are identified and picked out for the next step. The program is devised in MATLAB such that the parameters can be easily defined and changed for comparison. The final results are structured into 4 sections that specify an appropriate abatement method for each operator and machine, minimum allowance time for high-risk operators, required damping material for enclosures, and minimum total cost of these treatments. The validity of input data in addition to proper settings in the optimization model ensures the final solution is practical and economically reasonable. PMID:24934422

  15. Snake River Plain FORGE Well Data for WO-2

    DOE Data Explorer

    Robert Podgorney

    1991-07-29

    Well data for the WO-2 well located in eastern Snake River Plain, Idaho. This data collection includes lithology reports, borehole logs, temperature at depth data, neutron density and gamma data, and rock strength parameters for the WO-2 well. This collection of data has been assembled as part of the site characterization data used to develop the conceptual geologic model for the Snake River Plain site in Idaho, as part of phase 1 of the Frontier Observatory for Research in Geothermal Energy (FORGE) initiative. They were assembled by the Snake River Geothermal Consortium (SRGC), a team of collaborators that includes members from national laboratories, universities, industry, and federal agencies, lead by the Idaho National Laboratory (INL).

  16. Snake River Plain FORGE Well Data for INEL-1

    DOE Data Explorer

    Robert Podgorney

    1979-03-01

    Well data for the INEL-1 well located in eastern Snake River Plain, Idaho. This data collection includes caliper logs, lithology reports, borehole logs, temperature at depth data, neutron density and gamma data, full color logs, fracture analysis, photos, and rock strength parameters for the INEL-1 well. This collection of data has been assembled as part of the site characterization data used to develop the conceptual geologic model for the Snake River Plain site in Idaho, as part of phase 1 of the Frontier Observatory for Research in Geothermal Energy (FORGE) initiative. They were assembled by the Snake River Geothermal Consortium (SRGC), a team of collaborators that includes members from national laboratories, universities, industry, and federal agencies, lead by the Idaho National Laboratory (INL).

  17. Sensor Data Acquisition and Processing Parameters for Human Activity Classification

    PubMed Central

    Bersch, Sebastian D.; Azzi, Djamel; Khusainov, Rinat; Achumba, Ifeyinwa E.; Ries, Jana

    2014-01-01

    It is known that parameter selection for data sampling frequency and segmentation techniques (including different methods and window sizes) has an impact on the classification accuracy. For Ambient Assisted Living (AAL), no clear information to select these parameters exists, hence a wide variety and inconsistency across today's literature is observed. This paper presents the empirical investigation of different data sampling rates, segmentation techniques and segmentation window sizes and their effect on the accuracy of Activity of Daily Living (ADL) event classification and computational load for two different accelerometer sensor datasets. The study is conducted using an ANalysis Of VAriance (ANOVA) based on 32 different window sizes, three different segmentation algorithm (with and without overlap, totaling in six different parameters) and six sampling frequencies for nine common classification algorithms. The classification accuracy is based on a feature vector consisting of Root Mean Square (RMS), Mean, Signal Magnitude Area (SMA), Signal Vector Magnitude (here SMV), Energy, Entropy, FFTPeak, Standard Deviation (STD). The results are presented alongside recommendations for the parameter selection on the basis of the best performing parameter combinations that are identified by means of the corresponding Pareto curve. PMID:24599189

  18. 27 CFR 447.22 - Forgings, castings, and machined bodies.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ..., castings, extrusions, and machined bodies) which have reached a stage in manufacture where they are clearly... components, accessories, attachments and parts) then the particular forging, casting, extrusion,...

  19. Control of Groundwater Remediation Process as Distributed Parameter System

    NASA Astrophysics Data System (ADS)

    Mendel, M.; Kovács, T.; Hulkó, G.

    2014-12-01

    Pollution of groundwater requires the implementation of appropriate solutions which can be deployed for several years. The case of local groundwater contamination and its subsequent spread may result in contamination of drinking water sources or other disasters. This publication aims to design and demonstrate control of pumping wells for a model task of groundwater remediation. The task consists of appropriately spaced soil with input parameters, pumping wells and control system. Model of controlled system is made in the program MODFLOW using the finitedifference method as distributed parameter system. Control problem is solved by DPS Blockset for MATLAB & Simulink.

  20. TRITIUM AGING EFFECTS ON THE FRACTURE TOUGHNESS PROPERTIES OF FORGED STAINLESS STEEL

    SciTech Connect

    Morgan, M

    2008-04-14

    The fracture toughness properties of Type 21-6-9 stainless steel were measured for forgings in the unexposed, hydrogen-exposed, and tritium-exposed-and-aged conditions. Fracture toughness samples were cut from conventionally-forged and high-energy-rate-forged forward-extruded cylinders and mechanically tested at room temperature using ASTM fracture-toughness testing procedures. Some of the samples were exposed to either hydrogen or tritium gas (340 MPa, 623 K) prior to testing. Tritium-exposed samples were aged for up to seven years and tested periodically in order to measure the effect on fracture toughness of {sup 3}He from radioactive tritium decay. The results show that hydrogen-exposed and tritium-exposed samples had lower fracture- toughness values than unexposed samples and that fracture toughness decreased with increasing decay {sup 3}He content. Forged steels were more resistant to the embrittling effects of tritium and decay {sup 3}He than annealed steels, although their fracture-toughness properties depended on the degree of sensitization that occurred during processing. The fracture process was dominated by microvoid nucleation, growth and coalescence; however, the size and spacing of microvoids on the fracture surfaces were affected by hydrogen and tritium with the lowest-toughness samples having the smallest microvoids and finest spacing.

  1. 77 FR 23496 - Boundary Revision of Valley Forge National Historical Park

    Federal Register 2010, 2011, 2012, 2013, 2014

    2012-04-19

    ... National Park Service Boundary Revision of Valley Forge National Historical Park AGENCY: National Park... to the boundary of Valley Forge National Historical Park, pursuant to the authority specified below... ``Valley Forge National Historical Park Proposed Boundary Expansion, Montgomery County,...

  2. Roll compaction process modeling: transfer between equipment and impact of process parameters.

    PubMed

    Souihi, Nabil; Reynolds, Gavin; Tajarobi, Pirjo; Wikström, Håkan; Haeffler, Gunnar; Josefson, Mats; Trygg, Johan

    2015-04-30

    In this study, the roll compaction of an intermediate drug load formulation was performed using horizontally and vertically force fed roll compactors. The horizontally fed roll compactor was equipped with an instrumented roll technology allowing the direct measurement of normal stress at the roll surface, while the vertically fed roll compactor was equipped with a force gauge between the roll axes. Furthermore, characterization of ribbons, granules and tablets was also performed. Ribbon porosity was primarily found to be a function of normal stress, exhibiting a quadratic relationship thereof. A similar quadratic relationship was also observed between roll force and ribbon porosity of the vertically fed roll compactor. The predicted peak pressure (Pmax) using the Johanson model was found to be higher than the measured normal stress, however, the predicted Pmax correlated well with the ribbon relative density/porosity and the majority of downstream properties of granules and tablets, demonstrating its use as a scale-independent parameter. A latent variable model was developed for both the horizontal and vertical fed roll compactors to express ribbon porosity as a function of geometric and process parameters. The model validation, performed with new data, resulted in overall good predictions. This study successfully demonstrated the scale up/transfer between two different roll compactors and revealed that the combined use of design of experiments, latent variable models and in silico predictions result in better understanding of the critical process parameters in roll compaction. PMID:25701630

  3. online Surveillance of Industrial Processes with Correlated Parameters

    Energy Science and Technology Software Center (ESTSC)

    1996-12-18

    SMP is a system for online surveillance of industrial processes or machinery for determination of the incipience or onset of abnormal operating conditions. SMP exploits the cross correlation between all of the sensors that are available on the system under surveillance to provide an extremely high sensitivity for annunciation of subtle disturbances in process variables.

  4. Fallon FORGE 3D Geologic Model

    DOE Data Explorer

    Doug Blankenship

    2016-03-01

    An x,y,z scattered data file for the 3D geologic model of the Fallon FORGE site. Model created in Earthvision by Dynamic Graphic Inc. The model was constructed with a grid spacing of 100 m. Geologic surfaces were extrapolated from the input data using a minimum tension gridding algorithm. The data file is tabular data in a text file, with lithology data associated with X,Y,Z grid points. All the relevant information is in the file header (the spatial reference, the projection etc.) In addition all the fields in the data file are identified in the header.

  5. Forging Oxide-Dispersion-Strengthened Superalloys

    NASA Technical Reports Server (NTRS)

    Harf, F. H.; Glasgow, T. K.; Moracz, D. J.; Austin, C. M.

    1986-01-01

    Cladding of mild steel prevents surface cracking when alloy contacts die. Continual need for improvements in properties of alloys capable of withstanding elevated temperatures. Accomplished by using oxide-dispersion-strengthed superalloys such as Inconel Alloy MA 6000. Elevated tensile properties of forged alloy equal those of hot-rolled MA 6000 bar. Stress-rupture properties somewhat lower than those of bar stock but, at 1,100 degrees C, exceed those of strongest commercial single crystal, directionally solidified and conventionally cast superalloys.

  6. Effect of processes and processing parameters on 3-D braided preforms for composites

    SciTech Connect

    Li, W.; Shiekh, A.E.

    1988-07-01

    A general comparison about the processes, the structures and tensile properties of two 3-D braiding techniques are presented in this paper. The yarn orientation, braid width, braider curvature at fabric surface, and yarn volume fraction of both the 4-step and 2-step braids are analytically predicted in terms of the normalized cycle length which is directly related to the machine operating conditions. The extreme values of the parameters are discussed and compared. Results of the tensile properties of the braids are presented and discussed in terms of the structure differences. 11 references, 9 figures, 1 table.

  7. Protostars: Forges of cosmic rays?

    NASA Astrophysics Data System (ADS)

    Padovani, M.; Marcowith, A.; Hennebelle, P.; Ferrière, K.

    2016-05-01

    processes, and on the formation of pre-biotic molecules.

  8. Effect of some process parameters in enzymatic dyeing of wool.

    PubMed

    Tzanov, Tzanko; Silva, Carla Joana; Zille, Andrea; Oliveira, Jovita; Cavaco-Paulo, Artur

    2003-10-01

    This article reports on the dyeing of wool using an enzymatic system comprising laccase; dye precursor, 2,5-diaminobenzenesulfonic acid; and dye modifiers, catechol and resorcinol. Enzymatic dyeing was performed as a batchwise process at the temperature and pH of maximum enzyme activity. The effects of the process variables reaction time, enzyme, and modifier concentration on fabric color were studied, according to an appropriate experimental design. Different hues and depths of shades could be achieved by varying the concentration of the modifiers and the time of laccase treatment. The duration of the enzymatic reaction appeared to be the most important factor in the dyeing process. Thus, the dyeing process, performed at low temperature and mild pH, was advantageous in terms of reduced enzyme and chemical dosage. PMID:14566065

  9. Signal processing for longitudinal parameters of the Tevatron beam

    SciTech Connect

    Pordes, S.; Crisp, J.; Fellenz, B.; Flora, R.; Para, A.; Tollestrup, A.V.; /Fermilab

    2005-05-01

    We describe the system known as the Tevatron SBD [1] which is used to provide information on the longitudinal parameters of coalesced beam bunches in the Tevatron. The system has been upgraded over the past year with a new digitizer and improved software. The quantities provided for each proton and antiproton bunch include the intensity, the longitudinal bunch profile, the timing of the bunch with respect to the low-level RF, the momentum spread and the longitudinal emittance. The system is capable of 2 Hz operation and is run at 1 Hz.

  10. 22 CFR 121.10 - Forgings, castings and machined bodies.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 22 Foreign Relations 1 2011-04-01 2011-04-01 false Forgings, castings and machined bodies. 121.10... STATES MUNITIONS LIST Enumeration of Articles § 121.10 Forgings, castings and machined bodies. Articles..., castings, extrusions and machined bodies) which have reached a stage in manufacture where they are...

  11. 22 CFR 121.10 - Forgings, castings and machined bodies.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... 22 Foreign Relations 1 2013-04-01 2013-04-01 false Forgings, castings and machined bodies. 121.10... STATES MUNITIONS LIST Enumeration of Articles § 121.10 Forgings, castings and machined bodies. Articles on the U.S. Munitions List include articles in a partially completed state (such as...

  12. 22 CFR 121.10 - Forgings, castings and machined bodies.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 22 Foreign Relations 1 2012-04-01 2012-04-01 false Forgings, castings and machined bodies. 121.10... STATES MUNITIONS LIST Enumeration of Articles § 121.10 Forgings, castings and machined bodies. Articles on the U.S. Munitions List include articles in a partially completed state (such as...

  13. 27 CFR 447.22 - Forgings, castings, and machined bodies.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 3 2012-04-01 2010-04-01 true Forgings, castings, and... IMPLEMENTS OF WAR The U.S. Munitions Import List § 447.22 Forgings, castings, and machined bodies. Articles on the U.S. Munitions Import List include articles in a partially completed state (such as...

  14. 27 CFR 447.22 - Forgings, castings, and machined bodies.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 3 2013-04-01 2013-04-01 false Forgings, castings, and... IMPLEMENTS OF WAR The U.S. Munitions Import List § 447.22 Forgings, castings, and machined bodies. Articles on the U.S. Munitions Import List include articles in a partially completed state (such as...

  15. 27 CFR 447.22 - Forgings, castings, and machined bodies.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 3 2014-04-01 2014-04-01 false Forgings, castings, and... IMPLEMENTS OF WAR The U.S. Munitions Import List § 447.22 Forgings, castings, and machined bodies. Articles on the U.S. Munitions Import List include articles in a partially completed state (such as...

  16. 17. Forge building, fuel storage shed, and foundry, 1906 Photocopied ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    17. Forge building, fuel storage shed, and foundry, 1906 Photocopied from a photograph by Thomas S. Bronson, 'Group at Whitney Factory, 5 November 1906,' NHCHSL. The most reliable view of the fuel storage sheds and foundry, together with a view of the forge building. - Eli Whitney Armory, West of Whitney Avenue, Armory Street Vicinity, Hamden, New Haven County, CT

  17. View west of small tooling and forging dies in Blacksmith ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    View west of small tooling and forging dies in Blacksmith Shop, Boilermakers Department, east side of building 57; during World War II approximately forty women were employed as blacksmith's forging a variety of small tools; these may be the tools they used. - Naval Base Philadelphia-Philadelphia Naval Shipyard, Structure Shop, League Island, Philadelphia, Philadelphia County, PA

  18. 18. INTERIOR VIEW OF ROUGH FORGED TOOLS (FOREGROUND) WHICH ARE ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    18. INTERIOR VIEW OF ROUGH FORGED TOOLS (FOREGROUND) WHICH ARE PRE-HEATED IN THE FURNACE (REAR RIGHT) AND THEN FORGED WITH THE BRADLEY HAMMER (LEFT) AS SHOWN BY JAMES GLASPELL - Warwood Tool Company, Foot of Nineteenth Street, Wheeling, Ohio County, WV

  19. Physics and Technological Training in Bulgarian Forge Craft

    NASA Astrophysics Data System (ADS)

    Petkova, Petya N.; Velcheva, Keranka G.

    2010-01-01

    The contemporary world regenerates and preserves the traditions of decorative—applied art and the national crafts. This brings up young generation and helps them to uncover the sources of national culture. In the commonly educational system the technological training realizes succession of new methods for national and applied art. The aim is examination of the national crafts as technological processes for cultivation of different metal constructions. There are enforced physical laws here. Seven basic groups of forging methods consider in Bulgarian tradition craft as heat treatment, plastic deformation and applying of different tensions. This gives information about morphology of construction after applying of stress, enlarging or decreasing of the linear sizes, structure change and the change of physical and mechanical properties.

  20. Dimensionless Numbers Expressed in Terms of Common CVD Process Parameters

    NASA Technical Reports Server (NTRS)

    Kuczmarski, Maria A.

    1999-01-01

    A variety of dimensionless numbers related to momentum and heat transfer are useful in Chemical Vapor Deposition (CVD) analysis. These numbers are not traditionally calculated by directly using reactor operating parameters, such as temperature and pressure. In this paper, these numbers have been expressed in a form that explicitly shows their dependence upon the carrier gas, reactor geometry, and reactor operation conditions. These expressions were derived for both monatomic and diatomic gases using estimation techniques for viscosity, thermal conductivity, and heat capacity. Values calculated from these expressions compared well to previously published values. These expressions provide a relatively quick method for predicting changes in the flow patterns resulting from changes in the reactor operating conditions.

  1. Implant for in-vivo parameter monitoring, processing and transmitting

    SciTech Connect

    Ericson, Milton N.; McKnight, Timothy E.; Smith, Stephen F.; Hylton, James O.

    2009-11-24

    The present invention relates to a completely implantable intracranial pressure monitor, which can couple to existing fluid shunting systems as well as other internal monitoring probes. The implant sensor produces an analog data signal which is then converted electronically to a digital pulse by generation of a spreading code signal and then transmitted to a location outside the patient by a radio-frequency transmitter to an external receiver. The implanted device can receive power from an internal source as well as an inductive external source. Remote control of the implant is also provided by a control receiver which passes commands from an external source to the implant system logic. Alarm parameters can be programmed into the device which are capable of producing an audible or visual alarm signal. The utility of the monitor can be greatly expanded by using multiple pressure sensors simultaneously or by combining sensors of various physiological types.

  2. Quench-Induced Stresses in AA2618 Forgings for Impellers: A Multiphysics and Multiscale Problem

    NASA Astrophysics Data System (ADS)

    Chobaut, Nicolas; Saelzle, Peter; Michel, Gilles; Carron, Denis; Drezet, Jean-Marie

    2015-05-01

    In the fabrication of heat-treatable aluminum parts such as AA2618 compressor impellers for turbochargers, solutionizing and quenching are key steps to obtain the required mechanical characteristics. Fast quenching is necessary to avoid coarse precipitation as it reduces the mechanical properties obtained after heat treatment. However, fast quenching induces residual stresses that can cause unacceptable distortions during machining. Furthermore, the remaining residual stresses after final machining can lead to unfavorable stresses in service. Predicting and controlling internal stresses during the whole processing from heat treatment to final machining is therefore of particular interest to prevent negative impacts of residual stresses. This problem is multiphysics because processes such as heat transfer during quenching, precipitation phenomena, thermally induced deformations, and stress generation are interacting and need to be taken into account. The problem is also multiscale as precipitates of nanosize form during quenching at locations where the cooling rate is too low. This precipitation affects the local yield strength of the material and thus impacts the level of macroscale residual stresses. A thermomechanical model accounting for precipitation in a simple but realistic way is presented. Instead of modelling precipitation that occurs during quenching, the model parameters are identified using a limited number of tensile tests achieved after representative interrupted cooling paths in a Gleeble machine. The simulation results are compared with as-quenched residual stresses in a forging measured by neutron diffraction.

  3. A Multiresolution Method for Parameter Estimation of Diffusion Processes

    PubMed Central

    Kou, S. C.; Olding, Benjamin P.; Lysy, Martin; Liu, Jun S.

    2014-01-01

    Diffusion process models are widely used in science, engineering and finance. Most diffusion processes are described by stochastic differential equations in continuous time. In practice, however, data is typically only observed at discrete time points. Except for a few very special cases, no analytic form exists for the likelihood of such discretely observed data. For this reason, parametric inference is often achieved by using discrete-time approximations, with accuracy controlled through the introduction of missing data. We present a new multiresolution Bayesian framework to address the inference difficulty. The methodology relies on the use of multiple approximations and extrapolation, and is significantly faster and more accurate than known strategies based on Gibbs sampling. We apply the multiresolution approach to three data-driven inference problems – one in biophysics and two in finance – one of which features a multivariate diffusion model with an entirely unobserved component. PMID:25328259

  4. The Effects of Forming Parameters on Conical Ring Rolling Process

    PubMed Central

    Meng, Wen; Zhao, Guoqun; Guan, Yanjin

    2014-01-01

    The plastic penetration condition and biting-in condition of a radial conical ring rolling process with a closed die structure on the top and bottom of driven roll, simplified as RCRRCDS, were established. The reasonable value range of mandrel feed rate in rolling process was deduced. A coupled thermomechanical 3D FE model of RCRRCDS process was established. The changing laws of equivalent plastic strain (PEEQ) and temperature distributions with rolling time were investigated. The effects of ring's outer radius growth rate and rolls sizes on the uniformities of PEEQ and temperature distributions, average rolling force, and average rolling moment were studied. The results indicate that the PEEQ at the inner layer and outer layer of rolled ring are larger than that at the middle layer of ring; the temperatures at the “obtuse angle zone” of ring's cross-section are higher than those at “acute angle zone”; the temperature at the central part of ring is higher than that at the middle part of ring's outer surfaces. As the ring's outer radius growth rate increases at its reasonable value ranges, the uniformities of PEEQ and temperature distributions increase. Finally, the optimal values of the ring's outer radius growth rate and rolls sizes were obtained. PMID:25202716

  5. A stochastic process approach of the drake equation parameters

    NASA Astrophysics Data System (ADS)

    Glade, Nicolas; Ballet, Pascal; Bastien, Olivier

    2012-04-01

    The number N of detectable (i.e. communicating) extraterrestrial civilizations in the Milky Way galaxy is usually calculated by using the Drake equation. This equation was established in 1961 by Frank Drake and was the first step to quantifying the Search for ExtraTerrestrial Intelligence (SETI) field. Practically, this equation is rather a simple algebraic expression and its simplistic nature leaves it open to frequent re-expression. An additional problem of the Drake equation is the time-independence of its terms, which for example excludes the effects of the physico-chemical history of the galaxy. Recently, it has been demonstrated that the main shortcoming of the Drake equation is its lack of temporal structure, i.e., it fails to take into account various evolutionary processes. In particular, the Drake equation does not provides any error estimation about the measured quantity. Here, we propose a first treatment of these evolutionary aspects by constructing a simple stochastic process that will be able to provide both a temporal structure to the Drake equation (i.e. introduce time in the Drake formula in order to obtain something like N(t)) and a first standard error measure.

  6. Structure of magnesium alloy MA14 after multistep isothermal forging and subsequent isothermal rolling

    NASA Astrophysics Data System (ADS)

    Nugmanov, D. R.; Sitdikov, O. Sh.; Markushev, M. V.

    2015-10-01

    Optical metallography and electron microscopy have been used to analyze the structural changes in magnesium MA14 alloy subjected to processing that combines multistep isothermal forging and isothermal rolling. It has been found that forging of a bulk workpiece leads to the formation of a structure, 85-90% of which consists of recrystallized grains with an average size of less than 5 µm. Subsequent rolling results in a completely recrystallized structure with a grain size of 1-2 µm. It is shown that the resultant structural states are characterized by grain size nonuniformity inherited from the initial hot-pressed semi-finished product. The nature and features of crystallization processes that take place in the alloy during processing are discussed.

  7. Geomechanical Parameters in Fracturing Process of Layered Rocks

    NASA Astrophysics Data System (ADS)

    Mighani, S.; Sondergeld, C. H.; Rai, C. S.

    2013-12-01

    Hydraulic fracturing is crucial to geothermal and hydrocarbon recovery. Predicting performance based on rock characteristics (micro and macro) is essential to effective stimulation. We studied two extreme rock types: 1) Lyons sandstone, a brittle, low porosity, low permeability, weakly anisotropic material and 2) pyrophyllite, a strongly anisotropic metamorphic rock similar chemically and mechanically to shale, having extremely low porosity and permeability. Mineralogy, porosity, permeability, mercury capillary pressure, grain size, μ-CT imaging and elastic anisotropy analysis describe these rocks. Brazilian disk tests were carried to observe the fracture initiation and propagation under tension. Fracture propagation velocity is measured using a high speed digital camera. Strain gauges and acoustic emission (AE) sensors recorded deformation leading to and during failure. SEM imaging and surface profilometry were used to study the post-failure fracture systems and failed surface topology. The fracture process zone (FPZ) is mapped and evaluated using a mosaic of stitched SEM images. The fracture permeability was measured as a function of effective stress and compared to fracture permeability models. The effect of anisotropy on fracturing (Mode I and Mode II fractures) was also investigated rotating the fabric direction of the tested disks relative to the loading axis through increments of 15 degrees. Results indicate differences in fracturing process of these two rock types. Pyrophyllite displays a localized ductile behavior in the process zone resulting in a narrower fracture with a higher propagation velocity and far less AE activity. Pyrophyllite shows 70 % higher tensile strength compared to Lyons sandstone even though it becomes ductile at much lower pressures. The sandstone shows a wide brittle fracture with larger FPZ and better permeability at elevated effective pressures. The greater number of AE activity associated with higher energy events confirms the

  8. Hot Superplastic Powder Forging for Transparent nanocrystalline Ceramics

    SciTech Connect

    Cannon, W. Roger

    2006-05-22

    The program explored a completely new, economical method of manufacturing nanocrystalline ceramics, Hot Superplastic Powder Forging (HSPF). The goal of the work was the development of nanocrystalline/low porosity optically transparent zirconia/alumina. The high optical transparency should result from lack of grain boundary scattering since grains will be smaller than one tenth the wavelength of light and from elimination of porosity. An important technological potential for this process is manufacturing of envelopes for high-pressure sodium vapor lamps. The technique for fabricating monolithic nanocrystalline material does not begin with powder whose particle diameter is <100 nm as is commonly done. Instead it begins with powder whose particle diameter is on the order of 10-100 microns but contains nanocrystalline crystallites <<100 nm. Spherical particles are quenched from a melt and heat treated to achieve the desired microstructure. Under a moderate pressure within a die or a mold at temperatures of 1100C to 1300C densification is by plastic flow of superplastic particles. A nanocrystalline microstructure results, though some features are greater than 100nm. It was found, for instance, that in the fully dense Al2O3-ZrO2 eutectic specimens that a bicontinuous microstructure exists containing <100 nm ZrO2 particles in a matrix of Al2O3 grains extending over 1-2 microns. Crystallization, growth, phase development and creep during hot pressing and forging were studied for several compositions and so provided some details on development of polycrystalline microstructure from heating quenched ceramics.

  9. Meta-Model Based Optimisation Algorithms for Robust Optimization of 3D Forging Sequences

    SciTech Connect

    Fourment, Lionel

    2007-04-07

    In order to handle costly and complex 3D metal forming optimization problems, we develop a new optimization algorithm that allows finding satisfactory solutions within less than 50 iterations (/function evaluation) in the presence of local extrema. It is based on the sequential approximation of the problem objective function by the Meshless Finite Difference Method (MFDM). This changing meta-model allows taking into account the gradient information, if available, or not. It can be easily extended to take into account uncertainties on the optimization parameters. This new algorithm is first evaluated on analytic functions, before being applied to a 3D forging benchmark, the preform tool shape optimization that allows minimizing the potential of fold formation during the two-stepped forging sequence.

  10. Factors Affecting Scale Adhesion on Steel Forgings

    NASA Astrophysics Data System (ADS)

    Zitterman, J. A.; Bacco, R. P.; Boggs, W. E.

    1982-04-01

    Occasionally, undesirable "sticky" adherent scale forms on low-carbon steel during reheating for hot forging. The mechanical abrading or chemical pickling required to remove this scale adds appreciably to the fabrication cost. Characterization of the steel-scale system by metallographic examination, x-ray diffraction, and electron-probe microanalysis revealed that nickel, silicon, and/or sulfur might be involved in the mechanism of sticky-scale formation. Laboratory reheating tests were conducted on steels with varied concentrations of nickel and silicon in atmospheres simulating those resulting from burning natural gas or sulfur-bearing fuels. Subsequent characterization of the scale formed during the tests tends to confirm that the composition of the steel, especially increased nickel and silicon contents, and the presence of the sulfur in the furnace atmosphere cause the formation of this undesirable scale.

  11. Optimization of process parameters for the manufacturing of rocket casings: A study using processing maps

    NASA Astrophysics Data System (ADS)

    Avadhani, G. S.

    2003-12-01

    Maraging steels possess ultrahigh strength combined with ductility and toughness and could be easily fabricated and heat-treated. Bulk metalworking of maraging steels is an important step in the component manufacture. To optimize the hot-working parameters (temperature and strain rate) for the ring rolling process of maraging steel used for the manufacture of rocket casings, a systematic study was conducted to characterize the hot working behavior by developing processing maps for γ-iron and an indigenous 250 grade maraging steel. The hot deformation behavior of binary alloys of iron with Ni, Co, and Mo, which are major constituents of maraging steel, is also studied. Results from the investigation suggest that all the materials tested exhibit a domain of dynamic recrystallization (DRX). From the instability maps, it was revealed that strain rates above 10 s-1 are not suitable for hot working of these materials. An important result from the stress-strain behavior is that while Co strengthens γ-iron, Ni and Mo cause flow softening. Temperatures around 1125 °C and strain rate range between 0.001 and 0.1 s-1 are suitable for the hot working of maraging steel in the DRX domain. Also, higher strain rates may be used in the meta-dynamic recrystallization domain above 1075 °C for high strain rate applications such as ring rolling. The microstructural mechanisms identified from the processing maps along with grain size analyses and hot ductility measurements could be used to design hot-working schedules for maraging steel.

  12. Grain size modeling and optimization of rotary forged Alloy 718

    SciTech Connect

    Domblesky, J.P.; Shivpuri, R.

    1997-04-01

    The study presented describes the simulation procedure and methodology used to develop two models for predicting recrystallized grain size in Alloy 718 billet. To simulate multiple pass forging of billet, controlled, high temperature compression testing was used to apply alternate deformation and dwell cycles to Alloy 718 specimens. Grain size obtained by simulation was found to be in excellent agreement with grain size from forged billet when cooling rate was included. The study also revealed that strain per pass and forging temperature were the predominant factors in controlling the recrystallized grain size. Both models were found to accurately predict the recrystallized grain size obtained by compression tests performed at super-solvus temperatures.

  13. Parallel investigation of double forged pure tungsten samples irradiated in three DPF devices

    NASA Astrophysics Data System (ADS)

    Gribkov, V. A.; Paduch, M.; Zielinska, E.; Laas, T.; Shirokova, V.; Väli, B.; Paju, J.; Pimenov, V. N.; Demina, E. V.; Latyshev, S. V.; Niemela, J.; Crespo, M.-L.; Cicuttin, A.; Talab, A. A.; Pokatilov, A.; Parker, M.

    2015-08-01

    The double forged pure tungsten (W) samples (supplied by IAEA CRP from the FZJ team in Juelich, Germany) were irradiated in DPF (dense plasma focus) devices PF-12, "Bora" and PF-1000 by hot plasma and fast ion streams. We have used the following analytical methods: microscopy (optical and scanning electron), X-ray photoelectron spectroscopy, electrical conductivity and microroughness measurements. The damage dependence of the tungsten grades on irradiation conditions and power flux densities of irradiation processes is discussed.

  14. [Correlation of dry granulation process parameters and granule quality based on multiple regression analysis].

    PubMed

    Cao, Han-Han; Du, Ruo-Fei; Yang, Jia-Ning; Feng, Yi

    2014-03-01

    In this paper, microcrystalline cellulose WJ101 was used as a model material to investigate the effect of various process parameters on granule yield and friability after dry granulation with a single factor and the effect of comprehensive inspection process parameters on the effect of granule yield and friability, then the correlation between process parameters and granule quality was established. The regress equation was established between process parameters and granule yield and friability by multiple regression analysis, the affecting the order of the size of the order of the process parameters on granule yield and friability was: rollers speed > rollers pressure > speed of horizontal feed. Granule yield was positively correlated with pressure and speed of horizontal feed and negatively correlated rollers speed, while friability was on the contrary. By comparison, fitted value and real value, fitted and real value are basically the same of no significant differences (P > 0.05) and with high precision and reliability. PMID:24961115

  15. A study on the performance of synthetic type charts when process parameters are estimated

    NASA Astrophysics Data System (ADS)

    You, Huay Woon; Khoo, Michael Boon Chong; Teh, Sin Yin

    2015-10-01

    There are two types of synthetic charts for monitoring the process mean, i.e. synthetic X ¯ chart and synthetic double sampling X ¯ chart (SDS X ¯ chart). In most applications, the process parameters, such as the in-control mean and the in-control standard deviation are usually unknown. Under such circumstances, both these process parameters need to be estimated from an in-control Phase I dataset. Thus, it is vital to study the performance of these charts when the process parameters are unknown. In this paper, the performance of two synthetic type charts with estimated process parameters will be studied. The average number of observations to signal (ANOS) criterion will be used to evaluate the performances of these charts. This study shows that the performances of synthetic type charts are significantly affected by the estimation of process parameters. Furthermore, a large number of Phase I samples is required so that the synthetic type charts with estimated process parameters will have reasonable performances as their corresponding known process parameters counterparts, especially when the sample size and size of process mean shift is small.

  16. FEA Based Tool Life Quantity Estimation of Hot Forging Dies Under Cyclic Thermo-Mechanical Loads

    NASA Astrophysics Data System (ADS)

    Behrens, B.-A.; Bouguecha, A.; Schäfer, F.; Hadifi, T.

    2011-01-01

    Hot forging dies are exposed during service to a combination of cyclic thermo-mechanical, tribological and chemical loads. Besides abrasive and adhesive wear on the die surface, fatigue crack initiation with subsequent fracture is one of the most frequent causes of failure. In order to extend the tool life, the finite element analysis (FEA) may serve as a means for process design and process optimisation. So far the FEA based estimation of the production cycles until initial cracking is limited as tool material behaviour due to repeated loading is not captured with the required accuracy. Material models which are able to account for cyclic effects are not verified for the fatigue life predictions of forging dies. Furthermore fatigue properties from strain controlled fatigue tests of relevant hot work steels are to date not available to allow for a close-to-reality fatigue life prediction. Two industrial forging processes, where clear fatigue crack initiation has been observed are considered for a fatigue analysis. For this purpose the relevant tool components are modelled with elasto-plastic material behaviour. The predicted sites, where crack initiation occurs, agree with the ones observed on the real die component.

  17. View facing east of top of quarry wall with forge ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    View facing east of top of quarry wall with forge site in foreground - Granite Hill Plantation, Quarry No. 4, South side of State Route 16, 1.3 miles northeast east of Sparta, Sparta, Hancock County, GA

  18. View northeast of tooling for forging marine hardware in blacksmith ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    View northeast of tooling for forging marine hardware in blacksmith shop, east side of building 57. - Naval Base Philadelphia-Philadelphia Naval Shipyard, Structure Shop, League Island, Philadelphia, Philadelphia County, PA

  19. 6. NORTH END OF MACHINE SHOP. FORGE SHOP (HAER No. ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    6. NORTH END OF MACHINE SHOP. FORGE SHOP (HAER No. CA-326-K) ON LEFT, FORD PLANT IN DISTANCE, NE BY 60. - Rosie the Riveter National Historical Park, Machine Shop, 1311 Canal Boulevard, Richmond, Contra Costa County, CA

  20. DETAIL VIEW OF BLACKSMITH'S FORGE AND WORK AREA ON WEST ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    DETAIL VIEW OF BLACKSMITH'S FORGE AND WORK AREA ON WEST SIDE OF UPPER TRAM TERMINAL, LOOKING EAST. FORGE IS IN FOREGROUND, WITH THE ANVIL BLOCK JUST TO THE RIGHT AND BEHIND IT. A TRAM CAR IS UPSIDE DOWN TO THE LEFT OF THE FORGE. THE PIPE GOING INTO THE FORGE ON THE RIGHT CARRIED COMPRESSED AIR TO BLOW THE COALS. AT CENTER RIGHT ON THE TRAM TERMINAL ARE THE OPENING AND CLOSING MECHANISMS FOR THE ORE BUCKETS. AT CENTER LEFT IS A BRAKE WHEEL. THE ANCHOR POINTS FOR THE STATIONARY TRAM CABLES ARE JUST BELOW THIS WHEEL. THE FRONT END OF THE TERMINAL IS JUST OFF FRAME ON THE RIGHT. - Keane Wonder Mine, Park Route 4 (Daylight Pass Cutoff), Death Valley Junction, Inyo County, CA

  1. FOUNDRY SHOP, FORGE SHOP, NORTH ARMORY, EAST ARMORY. Colt ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    FOUNDRY SHOP, FORGE SHOP, NORTH ARMORY, EAST ARMORY. - Colt Fire Arms Company, East Armory Building, 36-150 Huyshope Avenue, 17-170 Van Dyke Avenue, 49 Vredendale Avenue, Hartford, Hartford County, CT

  2. A marvel of medieval Indian metallurgy: Thanjavur's forge-welded iron cannon

    NASA Astrophysics Data System (ADS)

    Balasubramaniam, R.; Saxena, A.; Anantharaman, Tanjore R.; Reguer, S.; Dillmann, P.

    2004-01-01

    In this article, metallurgical aspects of a 17th century forge-welded iron cannon at Thanjavur are addressed, including an analysis of manufacturing methodology based on careful observation of its constructional details. Microstructural examination of iron from the cannon reveals that the iron was extracted from ore by the direct process. Thus, the cannon was fabricated by forge welding and not by casting. Electrochemical polarization studies indicate that the corrosion rate of the cannon iron can be compared to that of 0.05% carbon mild steel under complete immersion conditions. However, the atmospheric corrosion resistance of the cannon is far superior to that of modern steel and can be attributed to the formation of an adherent protective passive film. It is concluded that this cannon constitutes a marvel of medieval Indian metallurgical skill.

  3. An Advanced User Interface Approach for Complex Parameter Study Process Specification in the Information Power Grid

    NASA Technical Reports Server (NTRS)

    Yarrow, Maurice; McCann, Karen M.; Biswas, Rupak; VanderWijngaart, Rob; Yan, Jerry C. (Technical Monitor)

    2000-01-01

    The creation of parameter study suites has recently become a more challenging problem as the parameter studies have now become multi-tiered and the computational environment has become a supercomputer grid. The parameter spaces are vast, the individual problem sizes are getting larger, and researchers are now seeking to combine several successive stages of parameterization and computation. Simultaneously, grid-based computing offers great resource opportunity but at the expense of great difficulty of use. We present an approach to this problem which stresses intuitive visual design tools for parameter study creation and complex process specification, and also offers programming-free access to grid-based supercomputer resources and process automation.

  4. T3PS v1.0: Tool for Parallel Processing in Parameter Scans

    NASA Astrophysics Data System (ADS)

    Maurer, Vinzenz

    2016-01-01

    T3PS is a program that can be used to quickly design and perform parameter scans while easily taking advantage of the multi-core architecture of current processors. It takes an easy to read and write parameter scan definition file format as input. Based on the parameter ranges and other options contained therein, it distributes the calculation of the parameter space over multiple processes and possibly computers. The derived data is saved in a plain text file format readable by most plotting software. The supported scanning strategies include: grid scan, random scan, Markov Chain Monte Carlo, numerical optimization. Several example parameter scans are shown and compared with results in the literature.

  5. Probabilistic parameter estimation of activated sludge processes using Markov Chain Monte Carlo.

    PubMed

    Sharifi, Soroosh; Murthy, Sudhir; Takács, Imre; Massoudieh, Arash

    2014-03-01

    One of the most important challenges in making activated sludge models (ASMs) applicable to design problems is identifying the values of its many stoichiometric and kinetic parameters. When wastewater characteristics data from full-scale biological treatment systems are used for parameter estimation, several sources of uncertainty, including uncertainty in measured data, external forcing (e.g. influent characteristics), and model structural errors influence the value of the estimated parameters. This paper presents a Bayesian hierarchical modeling framework for the probabilistic estimation of activated sludge process parameters. The method provides the joint probability density functions (JPDFs) of stoichiometric and kinetic parameters by updating prior information regarding the parameters obtained from expert knowledge and literature. The method also provides the posterior correlations between the parameters, as well as a measure of sensitivity of the different constituents with respect to the parameters. This information can be used to design experiments to provide higher information content regarding certain parameters. The method is illustrated using the ASM1 model to describe synthetically generated data from a hypothetical biological treatment system. The results indicate that data from full-scale systems can narrow down the ranges of some parameters substantially whereas the amount of information they provide regarding other parameters is small, due to either large correlations between some of the parameters or a lack of sensitivity with respect to the parameters. PMID:24384542

  6. Parameter-Level Data Flow Modeling Oriented to Product Design Process

    NASA Astrophysics Data System (ADS)

    Li, Shen; Shao, Xiao Dong; Zhang, Zhi Hua; Ge, Xiao Bo

    2015-12-01

    In this paper, a method of data flow modeling for a product design process oriented to data parameter is proposed. The data parameters are defined, which are classified as the basic data parameters and complex data parameters. The mechanism of the mapping relationship between different forms of documents and some basic data parameters, and a data transmission based on parameters, are constructed. Aiming at the characteristics of the iterative design process, the parameters version mechanism including node modification and iteration information is proposed. The data parameters transmission relationships are represented by a parameters network model (PNM) based on a directed graph. Finally, through the table of data parameters mapping onto the workflow node and PNM, the data ports and data links in the data flow model are generated automatically by the program. Validation in the 15-meter-diameter S/Ka frequency band antenna design process of the “Reflector, Back frame and Center part design” data flow model shows that the method can effectively shorten the time of data flow modeling and improve the data transmission efficiency.

  7. Snake River Plain FORGE Site Characterization Data

    DOE Data Explorer

    Robert Podgorney

    2016-04-18

    The site characterization data used to develop the conceptual geologic model for the Snake River Plain site in Idaho, as part of phase 1 of the Frontier Observatory for Research in Geothermal Energy (FORGE) initiative. This collection includes data on seismic events, groundwater, geomechanical models, gravity surveys, magnetics, resistivity, magnetotellurics (MT), rock physics, stress, the geologic setting, and supporting documentation, including several papers. Also included are 3D models (Petrel and Jewelsuite) of the proposed site. Data for wells INEL-1, WO-2, and USGS-142 have been included as links to separate data collections. These data have been assembled by the Snake River Geothermal Consortium (SRGC), a team of collaborators that includes members from national laboratories, universities, industry, and federal agencies, lead by the Idaho National Laboratory (INL). Other contributors include the National Renewable Energy Laboratory (NREL), Lawrence Livermore National Laboratory (LLNL), the Center for Advanced Energy Studies (CEAS), the University of Idaho, Idaho State University, Boise State University, University of Wyoming, University of Oklahoma, Energy and Geoscience Institute-University of Utah, US Geothermal, Baker Hughes Campbell Scientific Inc., Chena Power, US Geological Survey (USGS), Idaho Department of Water Resources, Idaho Geological Survey, and Mink GeoHydro.

  8. Forging the future: the public health imperative.

    PubMed Central

    Allukian, M

    1993-01-01

    During the 1980s, national policy promoted military expenditures and downsized domestic programs. These priorities, along with tax reform and deregulation, created a "domestic gulf crisis" with a new wave of vulnerable populations--poor children, the homeless, the elderly, and the uninsured. Our lack of a national health program compounds the problem. The 1990s will be a decade of change and challenge. To forge a healthier and stronger future for our nation, we must implement five public health imperatives: (1) We must have a national health program that is universal, comprehensive, and prevention-oriented, with built-in assurances for quality, efficiency, and a strong public health infrastructure. (2) We must have a comprehensive national health education and promotion program for all schoolchildren. (3) Women must have freedom of choice. (4) Prevention and public health must become one of our country's highest health priorities. (5) The federal government must increase its leadership, commitments, and resources to reach the goals set forth in Healthy Communities 2000 and Healthy People 2000. PMID:8484444

  9. A split-optimization approach for obtaining multiple solutions in single-objective process parameter optimization.

    PubMed

    Rajora, Manik; Zou, Pan; Yang, Yao Guang; Fan, Zhi Wen; Chen, Hung Yi; Wu, Wen Chieh; Li, Beizhi; Liang, Steven Y

    2016-01-01

    It can be observed from the experimental data of different processes that different process parameter combinations can lead to the same performance indicators, but during the optimization of process parameters, using current techniques, only one of these combinations can be found when a given objective function is specified. The combination of process parameters obtained after optimization may not always be applicable in actual production or may lead to undesired experimental conditions. In this paper, a split-optimization approach is proposed for obtaining multiple solutions in a single-objective process parameter optimization problem. This is accomplished by splitting the original search space into smaller sub-search spaces and using GA in each sub-search space to optimize the process parameters. Two different methods, i.e., cluster centers and hill and valley splitting strategy, were used to split the original search space, and their efficiency was measured against a method in which the original search space is split into equal smaller sub-search spaces. The proposed approach was used to obtain multiple optimal process parameter combinations for electrochemical micro-machining. The result obtained from the case study showed that the cluster centers and hill and valley splitting strategies were more efficient in splitting the original search space than the method in which the original search space is divided into smaller equal sub-search spaces. PMID:27625978

  10. Plant parameters for plant functional groups of western rangelands to enable process-based simulation modeling

    Technology Transfer Automated Retrieval System (TEKTRAN)

    Regional environmental assessments with process-based models require realistic estimates of plant parameters for the primary plant functional groups in the region. “Functional group” in this context is an operational term, based on similarities in plant type and in plant parameter values. Likewise...

  11. Multiresponse Optimization of Process Parameters in Turning of GFRP Using TOPSIS Method

    PubMed Central

    Parida, Arun Kumar; Routara, Bharat Chandra

    2014-01-01

    Taguchi's design of experiment is utilized to optimize the process parameters in turning operation with dry environment. Three parameters, cutting speed (v), feed (f), and depth of cut (d), with three different levels are taken for the responses like material removal rate (MRR) and surface roughness (Ra). The machining is conducted with Taguchi L9 orthogonal array, and based on the S/N analysis, the optimal process parameters for surface roughness and MRR are calculated separately. Considering the larger-the-better approach, optimal process parameters for material removal rate are cutting speed at level 3, feed at level 2, and depth of cut at level 3, that is, v3-f2-d3. Similarly for surface roughness, considering smaller-the-better approach, the optimal process parameters are cutting speed at level 1, feed at level 1, and depth of cut at level 3, that is, v1-f1-d3. Results of the main effects plot indicate that depth of cut is the most influencing parameter for MRR but cutting speed is the most influencing parameter for surface roughness and feed is found to be the least influencing parameter for both the responses. The confirmation test is conducted for both MRR and surface roughness separately. Finally, an attempt has been made to optimize the multiresponses using technique for order preference by similarity to ideal solution (TOPSIS) with Taguchi approach. PMID:27437503

  12. Evolution of the Ultrasonic Inspection of Heavy Rotor Forgings Over the Last Decades

    NASA Astrophysics Data System (ADS)

    Zimmer, A.; Vrana, J.; Meiser, J.; Maximini, W.; Blaes, N.

    2010-02-01

    All types of heavy forgings that are used in energy machine industry, rotor shafts as well as discs, retaining rings or tie bolts are subject to extensive nondestructive inspections before they are delivered to the customer. Due to the availability of the parts in simple shapes, these forgings are very well suited for full volmetric inspections using ultrasound. In the beginning, these inspections were carried out manually, using straight beam probes and analogue equipment. Higher requirements in reliability, efficiency, safety and power output in the machines have lead to higher requirements for the ultrasonic inspection in the form of more scanning directions, higher sensitivity demands and improved documentation means. This and the increasing use of high alloy materials for ever growing parts, increase the need for more and more sophisticated methods for testing the forgings. Angle scans and sizing technologies like DGS have been implemented, and for more than 15 years now, mechanized and automated inspections have gained importance since they allow better documentation as well as easier evaluation of the recorded data using different views (B- C- or D-Scans), projections or tomography views. The latest major development has been the availability of phased array probes to increase the flexibility of the inspection systems. Many results of the ongoing research in ultrasonic's have not been implemented yet. Today's availability of fast computers, large and fast data storages allows saving RF inspection data and applying sophisticated signal processing methods. For example linear diffraction tomography methods like SAFT offer tools for 3D reconstruction of inspection data, simplifying sizing and locating of defects as well as for improving signal to noise ratios. While such methods are already applied in medical ultrasonic's, they are still to be implemented in the steel industry. This paper describes the development of the ultrasonic inspection of heavy forgings

  13. Cavitation and failure during hot forging of Ti-6Al-4V

    SciTech Connect

    Semiatin, S.L.; Goetz, R.L.; Seetharaman, V.; Shell, E.B.; Ghosh, A.K.

    1999-05-01

    The occurrence of cavity initiation and gross, free-surface fracture during subtransus hot pancake forging of Ti-6Al-4V with a transformed beta (colony) microstructure was established. Cavity initiation mechanisms were one of two distinct types. At temperatures approximately 75 C or more below the beta transus temperature (T{sub {beta}}), cavity initiation occurred at relatively low strains in the beta phase lying between the grain-boundary alpha phase and the lamellar colonies. By contrast, at temperatures near the transus (i.e., T {approx} T{sub {beta}} {minus} 25 C), cavity initiation occurred at much larger strains as a result of microfracture of partially-to-fully globularized alpha phase. Finite element method (FEM) modeling of the pancake forging process revealed that secondary tensile stresses were used to correlate both the cavity initiation and the gross free-surface fracture results to previous observations from uniaxial hot tension tests in which identical damage mechanisms had been observed. The tensile work criterion of Cockcroft and Latham (C + L) gave moderately good (quantitative) correlation between the forging and uniaxial tension behaviors. An alternate comparison based on the Rice and Tracey cavity growth model gave reasonable predictions of free-surface fracture but tended to overestimate the incidence of subsurface cavity initiation.

  14. Non-destructive Testing of Forged Metallic Materials by Active Infrared Thermography

    NASA Astrophysics Data System (ADS)

    Maillard, S.; Cadith, J.; Bouteille, P.; Legros, G.; Bodnar, J. L.; Detalle, V.

    2012-11-01

    Nowadays, infrared thermography is considered as the reference method in many applications such as safety, the inspection of electric installations, or the inspection of buildings' heat insulation. In recent years, the evolution of both material and data-processing tools also allows the development of thermography as a real non-destructive testing method. Thus, by subjecting the element to be inspected to an external excitation and by analyzing the propagation of heat in the examined zone, it is possible to highlight surface or subsurface defects such as cracks, delaminations, or corrosion. One speaks then about active infrared thermography. In this study, some results obtained during the collective studies carried out by CETIM and the University of Reims for the forging industry are presented. Various experimental possibilities offered by active thermography are presented and the interest in this method in comparison with the traditional non-destructive testing methods (penetrant testing and magnetic particle inspection) is discussed. For example, comparative results on a forged cracked hub, a steering joint, and a threaded rod are presented. They highlight the interest of infrared thermography stimulated by induction for forged parts.

  15. Optimization of image process parameters through factorial experiments using a flat panel detector

    NASA Astrophysics Data System (ADS)

    Norrman, Eva; Geijer, Håkan; Persliden, Jan

    2007-09-01

    In the optimization process of lumbar spine examinations, factorial experiments were performed addressing the question of whether the effective dose can be reduced and the image quality maintained by adjusting the image processing parameters. A 2k-factorial design was used which is a systematic and effective method of investigating the influence of many parameters on a result variable. Radiographic images of a Contrast Detail phantom were exposed using the default settings of the process parameters for lumbar spine examinations. The image was processed using different settings of the process parameters. The parameters studied were ROI density, gamma, detail contrast enhancement (DCE), noise compensation, unsharp masking and unsharp masking kernel (UMK). The images were computer analysed and an image quality figure (IQF) was calculated and used as a measurement of the image quality. The parameters with the largest influence on image quality were noise compensation, unsharp masking, unsharp masking kernel and detail contrast enhancement. There was an interaction between unsharp masking and kernel indicating that increasing the unsharp masking improved the image quality when combined with a large kernel size. Combined with a small kernel size however the unsharp masking had a deteriorating effect. Performing a factorial experiment gave an overview of how the image quality was influenced by image processing. By adjusting the level of noise compensation, unsharp masking and kernel, the IQF was improved to a 30% lower effective dose.

  16. Superplastic forging of aluminum 6061-silicon carbide(P) composites

    NASA Astrophysics Data System (ADS)

    Memongkol, Napisporn

    This work describes the processing and characterization of mechanically alloyed Al6061-SiCP composites. The SiC dispersion strengthened Al6061 was synthesized by mechanical alloying of SiC powder and Al6061 powder in an argon atmosphere followed by hot pressing or cold compaction and sinter forging in air. The microstructure of the Al-SiC composites showed a fine grain size of Al matrix with SiC particles and dispersoids distributed homogeneously in the Al matrix. The microstructure of unreinforced MA6061 showed a fine grain size with small dispersoids. The preferred orientation in these composites was measured using the neutron diffraction technique. The hot pressed material had a random texture while a <111> preferred texture was developed in the sinter forged samples. The amount of texture developed depends on the applied load but not on the sintering temperature. The compressive strengths of these composites (4%SiC and 8%SiC) were characterized in the temperatures range from 723 to 833K and at strain rates of 10-4 to 10-1 s-1 . The true compressive stress strain curves exhibit strain softening behavior. The results showed significantly higher strength than the base material. The strain rate sensitivity, m, from the compression test is much lower than required for superplastic behavior. Tensile tests on the MA Al-8%SiC composite and MA6061 monolithic material were performed at temperatures of 673, 723, and 773K and strain rates from 10-2 to 10 s-1 . The true tensile stress strain curves show the strain hardening behavior. The relationship between microstructure, texture, densification and mechanical properties was studied and the strengthening mechanisms were identified. Uniaxial consolidation experiments have been conducted at room temperature and elevated temperature for three different powders, Al6061, MA6061 and MA6061-8%SiC. The experiments illustrated that the densification mechanisms of the three different powders at room temperature are similar but they

  17. Camera calibration method for dimensional measurement of heavy forging in large scale

    NASA Astrophysics Data System (ADS)

    Liu, Bin; Hu, Chunhai; Song, Xiaoxue; Zhao, Zhenqing

    2009-07-01

    Camera calibration method plays an important role in the stereovision system to resolve the problems of dimensional measurement of heavy forging. Due to the intensive vibrating, the camera parameters must be calibrated every time after the action of the water press. This paper presents a method using the scene geometry to calibrate cameras. In the context of heavy machinery environments, the constraints which can be used are parallelism and orthogonality. These constraints lead to geometrically intuitive methods to calibrate the cameras. The huge forging equipment such as water press belongs to geometrically constrained object and insusceptible to vibrating, which gives natural prior knowledge and constraint conditions for 3-D reconstruction. The method focuses on the calibration of the extrinsic parameters which are subject to change since the effects of the workspace factors. The intrinsic parameters were calibrated in advance by an off-line method and were assumed as invariable. The results of simulation experiments demonstrate that the camera parameters could be calibrated effectively and achieve the real time need.

  18. Texture evolution in Al-Li 2195 alloy during net shape roll forging

    SciTech Connect

    Kalu, P.N.; Zhang, Lan

    1998-06-12

    The quest to manufacture low-cost, large complex structures with minimum material wastage has instigated research into near-net shape (NNS) technologies. In this paper, the microstructural and texture evolution in Al-Li 2195 alloy resulting from a specific NNS processing called roll forging was evaluated. The processing consists of five stages and combines conventional ingot conversion (stages I and II), back extrusion (stage III) and ring rolling to produce hollow cylinder (stage IV). Considerable potential exists for the property enhancement of the components produced by this processing method if a better understanding of the evolution of microstructure and texture is developed.

  19. Effect of spray drying processing parameters on the insecticidal activity of two encapsulated formulations of baculovirus

    Technology Transfer Automated Retrieval System (TEKTRAN)

    The aim of this work was to evaluate the effect of spray dryer processing parameters on the process yield and insecticidal activity of baculovirus to support the development of this beneficial group of microbes as biopesticides. For each of two baculoviruses [granulovirus (GV) from Pieris rapae (L....

  20. Effects of the Deslagging Process on some Physicochemical Parameters of Honey

    PubMed Central

    Ranjbar, Ali Mohammad; Sadeghpour, Omid; Khanavi, Mahnaz; Shams Ardekani, Mohammad Reza; Moloudian, Hamid; Hajimahmoodi, Mannan

    2015-01-01

    Some physicochemical parameters of honey have been introduced by the International Honey Commission to evaluate its quality and origin but processes such as heating and filtering can affect these parameters. In traditional Iranian medicine, deslagging process involves boiling honey in an equal volume of water and removing the slag formed during process. The aim of this study was to determine the effects of deslagging process on parameters of color intensity, diastase evaluation, electrical conductivity, pH, free acidity, refractive index, hydroxy methyl furfural (HMF), proline and water contents according to the International Honey Committee (IHC) standards. The results showed that deslagged honey was significantly different from control honey in terms of color intensity, pH, diastase number, HMF and proline content. It can be concluded that the new standards are needed to regulate deslagged honey. PMID:25901175

  1. Effects of the Deslagging Process on some Physicochemical Parameters of Honey.

    PubMed

    Ranjbar, Ali Mohammad; Sadeghpour, Omid; Khanavi, Mahnaz; Shams Ardekani, Mohammad Reza; Moloudian, Hamid; Hajimahmoodi, Mannan

    2015-01-01

    Some physicochemical parameters of honey have been introduced by the International Honey Commission to evaluate its quality and origin but processes such as heating and filtering can affect these parameters. In traditional Iranian medicine, deslagging process involves boiling honey in an equal volume of water and removing the slag formed during process. The aim of this study was to determine the effects of deslagging process on parameters of color intensity, diastase evaluation, electrical conductivity, pH, free acidity, refractive index, hydroxy methyl furfural (HMF), proline and water contents according to the International Honey Committee (IHC) standards. The results showed that deslagged honey was significantly different from control honey in terms of color intensity, pH, diastase number, HMF and proline content. It can be concluded that the new standards are needed to regulate deslagged honey. PMID:25901175

  2. High Temperature, Slow Strain Rate Forging of Advanced Disk Alloy ME3

    NASA Technical Reports Server (NTRS)

    Gabb, Timothy P.; OConnor, Kenneth

    2001-01-01

    The advanced disk alloy ME3 was designed in the HSR/EPM disk program to have extended durability at 1150 to 1250 F in large disks. This was achieved by designing a disk alloy and process producing balanced monotonic, cyclic, and time-dependent mechanical properties. combined with robust processing and manufacturing characteristics. The resulting baseline alloy, processing, and supersolvus heat treatment produces a uniform, relatively fine mean grain size of about ASTM 7, with as-large-as (ALA) grain size of about ASTM 3. There is a long term need for disks with higher rim temperature capabilities than 1250 F. This would allow higher compressor exit (T3) temperatures and allow the full utilization of advanced combustor and airfoil concepts under development. Several approaches are being studied that modify the processing and chemistry of ME3, to possibly improve high temperature properties. Promising approaches would be applied to subscale material, for screening the resulting mechanical properties at these high temperatures. n obvious path traditionally employed to improve the high temperature and time-dependent capabilities of disk alloys is to coarsen the grain size. A coarser grain size than ASTM 7 could potentially be achieved by varying the forging conditions and supersolvus heat treatment. The objective of this study was to perform forging and heat treatment experiments ("thermomechanical processing experiments") on small compression test specimens of the baseline ME3 composition, to identify a viable forging process allowing significantly coarser grain size targeted at ASTM 3-5, than that of the baseline, ASTM 7.

  3. Advanced rotor forgings for high-temperature steam turbines. Volume 2. Mechanical property evaluation. Final report. [CrMoV steels

    SciTech Connect

    Swaminathan, V.P.; Landes, J.D.

    1986-05-01

    Three advanced steel-melting processes - low-sulfur vacuum silicon deoxidation, electroslag remelting, and vacuum carbon deoxidation (VCD) - were applied to produce three CrMoV (ASTM A470, Class 8) steel forgings for steam turbine application. Ingots weighing about 100 t each were produced using these three processes, and rotors were forged with final weights of about 30 t each. Compared to the conventionally produced forgings, the advanced technology forgings show better tensile ductility and better uniformity along the radial and longitudinal directions. Charpy upper-shelf energy shows about 40% improvement, and no temper embrittlement was found using step-cooled and isothermal-aging treatments. Significant improvement in fracture toughness (K/sub IC/ and J/sub IC/) is realized for these forgings. Low-cycle fatigue life is better at high temperatures because of the absence of nonmetallic inclusions. Creep strength shows slight improvement. However, creep ductility is improved, probably because of low residual elements. The VCD forgings show excellent creep ductility, even with long lives. Both the toughness and creep properties are equal to or better than those of oil-quenched rotors produced by European practices. These improvements are attributed to cleaner steel, better control of ingot solidification, low residual elements (especially very low sulfur content), and the associated reduction of nonmetallic inclusions. These three rotors have been placed in service in three operating power plants in units rated at 520 MW each. Volume 1 of this report covers ingot and forging production, and volume 2 covers mechanical property evaluation. 40 refs., 84 figs., 15 tabs.

  4. Fatigue behavior of rolled and forged tungsten at 25°, 280° and 480 °C

    NASA Astrophysics Data System (ADS)

    Habainy, J.; Iyengar, S.; Lee, Y.; Dai, Y.

    2015-10-01

    Pure tungsten has been chosen as the target material at the European Spallation Source facility in Lund. Calculations show that the target temperature can reach 500 °C momentarily during the spallation process, leading to thermal fatigue. Target life estimations require fatigue data at different temperatures and this work focuses on generating such data for pure, unirradiated, rolled and forged tungsten in the range 25°-480 °C. For specimens oriented in the rolling direction, tensile tests at room temperature indicated Young's modulus values in the range 320-390 GPa, low levels of plasticity (<0.23%) and UTS values in the range 397 MPa (unpolished) and 705 MPa (Polished). UTS for forged specimens were around 500 MPa. Stress-controlled fatigue tests were conducted in the tensile regime, with a runout limit of 2 × 106 cycles. At 25 °C, unpolished specimens had fatigue limits of 150 MPa (rolling and transverse direction), and 175 MPa (forged). For polished specimens in the rolling direction, fatigue limits were higher at 237.5 MPa (25 °C) and 252.5 MPa (280 °C). The forged specimens showed slightly better fatigue properties and marginal cyclic hardening at 480 °C.

  5. Mechanistic basis for the effects of process parameters on quality attributes in high shear wet granulation.

    PubMed

    Badawy, Sherif I F; Narang, Ajit S; LaMarche, Keirnan; Subramanian, Ganeshkumar; Varia, Sailesh A

    2012-12-15

    Three model compounds were used to study the effect of process parameters on in-process critical material attributes and a final product critical quality attribute. The effect of four process parameters was evaluated using design of experiment approach. Batches were characterized for particle size distribution, density (porosity), flow, compaction, and dissolution rate. The mechanisms of the effect of process parameters on primary granule properties (size and density) were proposed. Water amount showed significant effect on granule size and density. The effect of impeller speed was dependent on the granule mechanical properties and efficiency of liquid distribution in the granulator. Blend density was found to increase rapidly during wet massing. Liquid addition rate was the least consequential factor and showed minimal impact on granule density and growth. Correlations of primary properties with granulation bulk powder properties (compaction and flow) and tablet dissolution were also identified. The effects of the process parameters on the bulk powder properties and tablet dissolution were consistent with their proposed link to primary granule properties. Understanding the impact of primary granule properties on bulk powder properties and final product critical quality attributes provides the basis for modulating granulation parameters in order to optimize product performance. PMID:22981985

  6. Survey of ultrasonic properties of aircraft Engine Titanium forgings

    NASA Astrophysics Data System (ADS)

    Yu, Linxiao; Margetan, F. J.; Thompson, R. B.; Degtyar, Andrei

    2002-05-01

    The Engine Titanium Consortium is surveying the ultrasonic properties of representative Ti-6-4 forgings used in rotating jet engine components. Velocity, attenuation and backscattered grain noise are being measured as function of position and inspection direction. The overall goal is to better understand and improve ultrasonic defect detection. This paper provides a summary of the work to date on this ongoing project. UT properties are generally found to vary systematically with position, and some properties, such as the grain noise anisotropy, appears to be well correlated to the local forging strain. We demonstrate how the UT properties from the highest noise region of a forging are being used to estimate defect detectability for improved inspection schemes.

  7. On selecting a prior for the precision parameter of Dirichlet process mixture models

    USGS Publications Warehouse

    Dorazio, R.M.

    2009-01-01

    In hierarchical mixture models the Dirichlet process is used to specify latent patterns of heterogeneity, particularly when the distribution of latent parameters is thought to be clustered (multimodal). The parameters of a Dirichlet process include a precision parameter ?? and a base probability measure G0. In problems where ?? is unknown and must be estimated, inferences about the level of clustering can be sensitive to the choice of prior assumed for ??. In this paper an approach is developed for computing a prior for the precision parameter ?? that can be used in the presence or absence of prior information about the level of clustering. This approach is illustrated in an analysis of counts of stream fishes. The results of this fully Bayesian analysis are compared with an empirical Bayes analysis of the same data and with a Bayesian analysis based on an alternative commonly used prior.

  8. Modelling of Viscoplastic Behaviour of IN718 Under Hot Forging Conditions

    SciTech Connect

    Lin, Y. P.; Lin, J.; Dean, T. A.; Brown, P. D.

    2007-04-07

    The mechanical properties of IN718 are directly related to microstructure such as grain size and the hardening mechanisms, which are effective during thermomechanical processing and subsequent heat treatment. In this study a set of unified viscoplastic constitutive equations were determined for IN718 from experimental data of hot forging conditions. Techniques were developed to analyse the reliability and consistency of the experimental data derived from different previous publications. In addition to viscoplastic flow of the material, the determined material model can be used to predict the evolution of dislocations, recrystallisation and grain size occurring during thermomechanical processing.

  9. Looking west inside of the machine/forge shop at chargin door ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    Looking west inside of the machine/forge shop at chargin door of the forging furnace. - U.S. Steel Edgar Thomson Works, Auxiliary Buildings & Shops, Along Monongahela River, Braddock, Allegheny County, PA

  10. Cellular scanning strategy for selective laser melting: Generating reliable, optimized scanning paths and processing parameters

    NASA Astrophysics Data System (ADS)

    Mohanty, Sankhya; Hattel, Jesper H.

    2015-03-01

    Selective laser melting is yet to become a standardized industrial manufacturing technique. The process continues to suffer from defects such as distortions, residual stresses, localized deformations and warpage caused primarily due to the localized heating, rapid cooling and high temperature gradients that occur during the process. While process monitoring and control of selective laser melting is an active area of research, establishing the reliability and robustness of the process still remains a challenge. In this paper, a methodology for generating reliable, optimized scanning paths and process parameters for selective laser melting of a standard sample is introduced. The processing of the sample is simulated by sequentially coupling a calibrated 3D pseudo-analytical thermal model with a 3D finite element mechanical model. The optimized processing parameters are subjected to a Monte Carlo method based uncertainty and reliability analysis. The reliability of the scanning paths are established using cumulative probability distribution functions for process output criteria such as sample density, thermal homogeneity, etc. A customized genetic algorithm is used along with the simulation model to generate optimized cellular scanning strategies and processing parameters, with an objective of reducing thermal asymmetries and mechanical deformations. The optimized scanning strategies are used for selective laser melting of the standard samples, and experimental and numerical results are compared.