Thor's Hammer

Thor’s Hammer: Design and Manufacturing Process Optimization of Cast Components 2021 SFSA Cast in Steel Competition: Technical Report Penn State Behrend Student Team Members: Kristen Collins, Senior Mechanical Engineer Jackson Craig, Senior Mechanical Engineer Matt Gielarowski, Senior Mechanical Engineer Austin Hankey, Senior Mechanical Engineer Penn State Behrend Faculty Advisor: Dr. Paul Carl Lynch, Ph. D Assistant Professor of Industrial Engineering Penn State Behrend Industry Sponsors: PRL Regal Cast, Lebanon, PA Urick Ductile Solutions, Erie, PA Background and Problem Statement Background: Traditionally, steel components for commercial and military applications have relied upon forging from wrought product to produce the unique balance of strength, hardness, ductility, and toughness required of these products. However, research within the metal casting industry has suggested that through the utilization of such techniques as fluid flow simulation, solidification modeling, and clean melting, casting can be used to create components with properties identical to forged components. Additionally, advancements in the printing of molds, cores, and patterns are continuously increasing the capability of casting to produce complex designs. Each year, the Steel Founder’s Society of America (SFSA) hosts a competition which focuses on the use of modern casting tools such as these to design and manufacture components that are typically produced with forging operations. This project involves participation in this year’s Cast in Steel competition to create a cast model of Thor’s Hammer. The creation of this cast hammer will try to validate the research that a properly processed casting can match the properties of forged components. The focus of the competition is in the creative implementation of the casting process to the fullest extent to produce a final design that is easily identifiable as the Marvel movie representation of Thor’s Hammer. Additionally, the functionality of the hammer will be evaluated based on a series of performance tests and expert revision. The specific tasks associated with each test are not disclosed to the design teams prior to the competition. However, it can be expected that the design will be tested in functions equivalent to that of a sledgehammer during demolition. In accordance with the competition limitations, the hammer in its completion, with both the head and the handle included, must be within the weight and length limitations of 6 lbs and 20 inches. The hammer must consist at least partially of components that have been cast with steel, though a specific percentage is not required. In compliance with the stipulation of being “easily recognizable as Thor’s Hammer” in terms of aesthetics, the head design will be a scale, either full or decreased, of the original 5 in by 5 in by 8 in dimensions. Within the competition testing, the design must be fully functional in the completion of tasks associated with a regular hammer, and primarily, in the high impact applications associated specifically with Thor’s Hammer. Little to no facial or structural deformation should occur under the loads induced throughout the performance tests. A combination of various manufacturing processes, including heat treatments, hipping, welding, and machining, may be used in addition to casting so as to meet the criteria for both the design and the capability. A variety of tactics, including but not limited to, CAD optimization, material selection, FEA, and fluid flow simulations, will be utilized to create a model of the highest functionality possible. Problem Statement: Design and manufacture a predominantly cast steel representation of Thor’s Hammer given SFSA’s competition specifications. Critical Technical Challenges • Design the hammer to undergo a series of unknown tests with unknown parameters o As part of the competition, the performance tests are not revealed to contestants • Design the hammer to take impact without deformation o Must withstand at least the average loads associated the functions of a hammer • Choose the manner of resembling the original model o Will be either full scale or scaled down from the original o Based on our interpretation of what classifies as “easily recognizable” • Choose the degree of solidity of the hammer head while also meeting the weight limitation o A solid cast would require a reduction in the volume of the head to nearly 1/10th of the original based on the density of steel o Increased proximity to full scale requires decreased solidity of the head • Determine the capabilities of the design in withstanding loads based on dimensional and solidity choices • Access the proper fluid flow software for realistically and accurately simulating casting processes • Conduct flow simulations to model the design-specific casting procedure and ensure the design provides the conditions necessary to produce a successful cast • Choose the method of casting capable of accurately producing the choice of scale and solidity • Choose the construction method for the handle that will provide the necessary strength and durability without significantly hindering the weight • Design method for creating a rigid handle that connects to the hammer’s internal structure • Determine the additional manufacturing processes needed to finish the hammer Overview of Project Objectives The over-arching objective associated with this project is to gain an understanding of the multitude of factors that affect a cast component and gain experience in completing the steps necessary for producing the final product. The project begins at the initial design step to design a castable Thor’s hammer and follows the component all the way through to the final manufacturing, finishing, and material testing. Doing so will involve self-completion of many of the procedures that typically relied on outsourcing to complete in previous years of competition participation. In the initial design stage, concept generation will be conducted where various designs will be produced and then narrowed down based on specified criteria. In this case, the components of each concept must not only be achievable by way of casting, but they must also uphold the competition-given limitations. After the designs are narrowed down to the best contenders, prototypes will be made to analyze the design functionality and determine any possible performance flaws. This phase will utilize 3D printing and design optimization within CAD to fine-tune the remaining designs. Analytical analysis will then be conducted within ANSYS to test the strength capability of each proposed hammer. This will clarify which design can maintain the most strength and resistance to deformation while also adhering to the 6 lb weight restriction. Upon selecting the most optimal model, mold design and fluid simulations will be conducted to ensure that the hammer dimensions are able to be cast based on the limitations given by the industry sponsor. Once the mold designs are created, they will be sent to the industry sponsor where they will print the molds and pour the molten steel into them to produce Thor’s hammer. This year’s industry sponsors will only be providing services for the mold manufacturing and the metal pouring. Finally, the casted hammers will be sent back from the industry partner, where the group will then implement various post processing techniques to prepare the hammer for competition testing along with conducting various material testing to analyze the hammer’s material properties. Description of Competition Limitations In the competition outline given by SFSA, there are primarily only three non-negotiable rules that all participants’ hammer designs must follow: the weight must be within 6 pounds, the length must be within 20 inches, and at least a portion of the hammer’s components must be cast with an alloy of steel. Thor’s Hammer is a one-handed hammer, and the size constraints are near the upper limit of one-handed hammers. Though not explicitly stated in the description, it can be inferred that the head is the component of the hammer for which casting is intended to be utilized. The head is both the primary functioning element of the tool and the major element that will be tested, therefore, casting the head aligns with the competition’s overall intent to highlight the capabilities of casting. Other factors to consider for success in the judgement process include overall quality, uniqueness of features, and functionality in the performance testing. However, only vague statements are made regarding these areas without provided metrics, therefore, the only strict rules governing submissions remain as those previously stated. With limitations being set in only these three designated areas, many of the key design choices are left up to the discretion of the designers. A wide variety of designs can be generated based on the strategy used to meet the requirements, as well as each team’s interpretation of Thor’s Hammer itself. The biggest influence on the chosen strategy, however, which is universal to all teams regardless of the design inspiration, is the difficulty in combining a 6 lb weight limit with the use of a steel alloy. Using a solid casting for the head would require that the dimensions be significantly scaled down from the original Marvel or Viking renditions. Therefore, any attempt to create a head of sizeable dimensions requires a very innovative casting design on behalf of each team. The contestants must determine how to structure the casted portion of the head such that it is within the designated weight but also maintains the structural integrity needed to perform as a hammer. This includes the scale of the outer dimensions, the internal geometries, specific alloy used, and so on. Furthermore, because additional non-cast elements are permitted, as well as various post processing operations such as machining; grinding; and welding, there are seemingly endless methods as to how the teams can transition from the appearance of the casting to the overall design appearance. Hammer Design Rationale: Marvel vs. Viking Mythology At the very base of this design process is determining what defines Thor’s Hammer and differentiates it from the average hammer.

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