Technology Areas

Improved Forging Manufacture

Intensive quenching is a revolutionary quenching technology that yields improved mechanical properties, reduces residual stresses, and improves overall forging quality. It enables substitution of low cost alloys for higher cost alloys, which in-turn would yield DLA significant cost savings.

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Improved Forging Tooling

Parts requiring large forging dies, such as landing gear bought by DLA Aviation and the military services, can cost hundreds of thousands of dollars and lead-times in excess of six months. Extending die life can therefore provide shorter lead times and substantial cost savings to DLA.

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Predictive Performance

Forging simulation or deformation modeling is known to reduce cost, improve forging processes, decrease lead-times, and increase quality of forgings. In previous DLA programs, SFTC demonstrated cost savings on the order of $1.9M. Simulation is an integral part of the forging process, in particular, closed-die forgings, and improvements in simulation and forging technologies result in cost, lead-time, surge capacity, and quality benefits to the DOD.

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Alternative of Improved Materials

It is anticipated the DLA will be supporting Unmanned Aerial Vehicles (UAV) in the future. This project serendipitously positions DLA as technology innovator and supplier for future systems it will support. Additionally, this project provides near term system improvement for UAV performance via improvements in UAV engine technology depending on advanced alloys.

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Prototypes

The DoD has a strategic need to develop and deploy the next generation of weapon systems for our warfighters. As the design of new weapons systems with forged components progresses from basic concepts to laboratory tests to relevant and operational environment testing, assistance is needed to address forging technical challenges and expedite the procurement of prototypes.

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FORGE-IT, AFCAT, MetalFACT

FORGE-IT addresses the myriad of supply chain and technical issues at the DLA Supply Centers, suppliers to DLA, and DOD locations by researching

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Portfolio of Projects

Improved Forging Manufacture
Project: Forging Process Improvement Using Intensive Quenching
Objective:

Demonstrate and deploy IQ Technolgies in forge shops. Reduce forging cycle times while improving quality. Improve forging properties. Reduce energy requirements in forge.

Solution:

Invoke IQ Technology which is a controlled, water deluge designed to strip away vapor bubbles on the surface of a part, extract heat, and reduce probability of distortion or cracking

Principal Investigator:
Improved Forging Tooling
Project: Innovations in Repair of Forging Dies
Objective:

Develop and implement in production cutting edge laser welding and cladding technologies to repair, upgrade and extend life of forging dies.

Solution:

Novel, laser-based cladding repair of tooling that offers new opportunities to repair and extend forging die life.

Principal Investigator:
Predictive Performance
Project: Design of Experiments (DOE) & Optimization
Objective:

Investigate, develop, test and implement a methodology for applying Design of Experiments (DOE) to forging design and manufacturing processes.

Solution:

By using Design of Experiment methods in a forging simulation environment allows a variety of process conditions can be explored rapidly. Process variations and design alternatives can be studied prior to production trials.

Project: Grain Size Modeling
Objective:

Investigate, develop, test and implement an empirical grain size model for IN-625. Reducing forging process design time by understanding the trade-offs between forging load, die fill and mechanical properties.

Solution:

Building a grain size model based on test data, with data conversion enhanced using DEFORM Material Suite. Then, testing the model on production processes (hammer and press).

Principal Investigator on Both Projects:
Alternative or Improved Materials
Project: Forged Fiber Reinforced Aluminum Engine Components
Objective

Ultimately deploy Fiber Reinforced Aluminum as a forged product.

Solution:

Develop near net shape forging practices for Fiber Reinforced Aluminum components to reduce machining waste, improve buy to fly ratio and reduce component cost for the warfighter.

Principal Investigator:
Prototypes
Project: Capability to Produce Prototypes or Demonstration Test Articles
Objective

Develop and validate a review process to evaluate requests for alternative product forms as compared to forgings.

Solution:

Acceptable alternative manufacturing methods were created and included in the Technical Data Package to allow for shorter production time.

Principal Investigator: