Project Technologies

IMPROVED DIE LUBRICATION - FORGING BILLET

Aluminum-based coatings have proven very effective in preventing decarburization, but compromised the surface of the steel. The coating needs to act as a barrier; it should not bond or react with the steel. The team envisions the use of automation and robotics to reduce the cost of application, improve cycle times, and to provide additional safety to the operator.

IMPROVED DIE LUBRICATION - FORGING DIE

Lubricants are applied to the faces of forging dies to reduce friction between the die and the workpiece, help metal fill the die cavity, and prevent metal build-up on the die surface. Prior results revealed significant potential for coatings and/or surface modification to reduce friction in forging processes.

WORKFORCE DEVELOPMENT

Virtual spaces have immense potential for sharing real time information, virtual toolkits for those who cannot attend in person, and forging-specific information to DOD personnel right from their computers. For a forge shop, it is important to understand how the specifications for material, process, etc. are applied. Specification support system toolkits reduce costs and lead times, and simplify the procurement process.

RESPONDENT AREA OF INTEREST

Ensuring part-to-part consistency and process integrity is crucial for the supply chain, as well as end-user performance. Developing new knowledge to replace longstanding skill and knowledge loss is also a factor. Considering the rapid advances in sensor application and data analytics, the forging supply chain stands to benefit tremendously.

PROTOTYPES

Forging furnace fuel consumption, constant refractory maintenance and unscheduled downtime is a significant cost driver for the forging process. Increasing furnace efficiencies and reducing unscheduled down times will lead to better quality precision forgings and increased production.

PROCUREMENT SOLUTIONS

FORGE-IT addresses the myriad of supply chain and technical issues at the DLA Supply Centers, suppliers to DLA, and DOD locations by researching and developing supply chain processes and tools for implementation to reduce lead-times, eliminate unfilled orders, improve quality, and reduce costs for forged parts.