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Enhancement of Aluminum Alloy Forgings Through Rapid Billet Heating

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Enhancement of Aluminum Alloy Forgings Through Rapid Billet Heating Supporting Industries Final Technical Report Enhancement of Aluminum Alloy Forgings through Rapid Billet Heating June 2006 Principal Investigators: Robert Kervick KomTeK Craig A. Blue and Puja B. Kadolkar Oak Ridge National Laboratory Teiichi Ando, Hui Lu, and Kozo Nakazawa Northeastern University Howard Mayer The Queen City Forging Company George Mochnal Forging Industry Association Managed by UT-Battelle, LLC ORNL/TM-2006/30 DOCUMENT AVAILABILITY Reports produced after January 1, 1996, are generally available free via the U.S. Department of Energy (DOE) Information Bridge. Web site http://www.osti.gov/bridge Reports produced before January 1, 1996, may be purchased by members of the public from the following source. National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 Telephone 703-605-6000 (1-800-553-6847) TDD 703-487-4639 Fax 703-605-6900 E-mail [email protected] Web site http://www.ntis.gov/support/ordernowabout.htm Reports are available to DOE employees, DOE contractors, Energy Technology Data Exchange (ETDE) representatives, and International Nuclear Information System (INIS) representatives from the following source. Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831 Telephone 865-576-8401 Fax 865-576-5728 E-mail [email protected] Web site http://www.osti.gov/contact.html FINAL TECHNICAL REPORT Project Title: Enhancement of Aluminum Alloy Forgings through Rapid Billet Heating Award No: DE-FC36-01ID14205 Recipient Organization: KomTeK 40 Rockdale St. Worcester, MA 01606 PI(s): Robert Kervick Phone: (508) 853-4500 E-mail: [email protected] National Laboratory: Oak Ridge National Laboratory 1 Bethel Valley Road MS 6083 Oak Ridge, TN 37831 PI(s): Craig A. Blue Puja B. Kadolkar Phone: (865) 574-4351 Phone: (865) 574-9956 E-mail: [email protected] E-mail: [email protected] Sub-Contractors: Northeastern University Department of Mechanical Engineering 343 Snell Engineering Boston, MA 02115 PI(s): Teiichi Ando Hui Lu Phone: (617) 373-3811 Phone: (617) 373-4497 E-mail: [email protected] E-mail: [email protected] Other Industrial Partners: The Queen City Forging Company 235 Tennyson Street Cincinnati, OH 45226 PI(s): Howard Mayer Phone: (513) 321-7200 E-mail: [email protected] Forging Industry Association 25 Prospect Avenue, Suite 300 Cleveland, OH 44115 PI(s): George Mochnal Phone: (216) 781-6260 E-mail: [email protected] Project Period: October 1, 2001– September 30, 2005 Date of Report: December 31, 2005 ORNL/TM-2006/30 Enhancement of Aluminum Alloy Forgings through Rapid Billet Heating Robert Kervick KomTeK Craig A. Blue Puja B. Kadolkar Oak Ridge National Laboratory Teiichi Ando Hui Lu Kozo Nakazawa Northeastern University Howard Mayer Queen City Forging Company George Mochnal Forging Industry Association June 2006 Prepared by OAK RIDGE NATIONAL LABORATORY P.O. Box 2008 Oak Ridge, Tennessee 37831-6283 managed by UT-Battelle, LLC for the U.S. DEPARTMENT OF ENERGY under contract DE-AC05-00OR22725 Acknowledgments and Disclaimer Acknowledgments This report is based upon work supported by the U.S. Department of Energy, Energy Efficiency and Renewable Energy, Industrial Technologies Program, Supporting Industries, under Award No. DE- FC36-01ID14205. The work performed in FY 2005 was supported by the Industrial Technologies Program, Industrial Materials for the Future and the Aluminum Industries of the Future. The authors would like to acknowledge Randy Howell, Jackie Mayotte, Vinod Sikka, Greg Engleman, Evan Ohriner, Michael K. Miller, Kaye Russell, Neal D. Evans and Kathy A. Thomas at ORNL for their valuable contributions and participation in the project. In addition, support from Hui Lu and Kozo Nakazawa of the Northeastern University is greatly appreciated. The authors would like to thank Dr. Peter Angelini for project guidance and Carolyn Moser for editorial review. Oak Ridge National Laboratory is operated by UT-Battelle, LLC, for the U.S. Department of Energy under contract DE-AC05-00OR22725. Disclaimer This report was prepared as a summary of research and development sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. ii Contents List of Figures ............................................................................................................................ v List of Tables ............................................................................................................................. vii Abbreviations and Acronyms .................................................................................................... ix 1. Executive Summary..................................................................................................................... 1 1.1 Research and Development................................................................................................ 1 1.2 Accomplishments............................................................................................................... 2 1.3 Commercialization ............................................................................................................. 3 1.4 Recommendations.............................................................................................................. 4 2. Introduction................................................................................................................................. 5 2.1 Domestic Technology Stauts Including Emerging Technology......................................... 5 2.2 The Infrared Heating Technology...................................................................................... 6 2.2 Benefits to the Domestic Technology and Industry Sector................................................ 6 2.4 Assumptions and Detailed Calculations of Energy Savings to the Overall Domestic Aluminum Industry ........................................................................................................... 8 3. Background................................................................................................................................. 11 3.1 Project Description............................................................................................................. 11 3.2 Project Objective ............................................................................................................... 11 3.3 Project Tasks ...................................................................................................................... 12 3.3.1 Task 1: Industry Analysis ................................................................................... 12 3.3.2 Task 2: Equipment Design and Fabrication ........................................................ 12 3.3.3 Task 3: Materials Development .......................................................................... 12 3.3.4 Task 4: Field Testing .......................................................................................... 13 3.3.5 Task 5: Energy Analysis ..................................................................................... 13 4. Results and Discussion ............................................................................................................... 15 4.1 Industry Analysis ............................................................................................................... 15 4.2 Equipment Design and Fabrication ................................................................................... 18 4.2.1 Rapid Infrared Heating Trials ............................................................................. 18 4.2.2 Fabrication of a Prototype System ...................................................................... 20 4.3 Materials Development ..................................................................................................... 20 4.3.1 Effects of Preheating ........................................................................................... 25 4.3.2 Forging and Cooling Conditions ......................................................................... 26 4.3.3 Effects of Heat Treatment ................................................................................... 28 4.3.4 Effects of Soaking Time ...................................................................................... 31 4.3.5 Effects of Aging Temperature ............................................................................ 31 4.3.6 Fatigue Testing ................................................................................................... 33 4.3.7 Mechanism of Grain Refinement ........................................................................ 37 4.3.8 Strengthening Mechanism in Forgings ............................................................... 37 4.4 Field Testing ....................................................................................................................
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