Forging Industry AssociationForging Industry Association

Roy W Hardy

Executive Vice PresidentExecutive Vice President

6.8.2010

Forging Industry AssociationForging Industry Association

• Headquartered in Cleveland, Ohio it represents the North American f i i d tforging industry.

• The membership (111 companies with 197 plants) accounts for approximately 73% of the custom forgings produced in the U.S., Canada and MexicoCanada and Mexico.

• The association also has members (88 companies) that supply equipment, materials or technical services to the industry.

• The Association is the only one of its kind in North America thatThe Association is the only one of its kind in North America that offers process-specific training, educational and technical services, as well as a common voice on legislative and regulatory issues.

• The Association, with its predecessor organizations, has served the f i i d i 1913forging industry since 1913.

What is forging?What is forging?

• Forging is one of the oldest known metalworking processes where metal is pressed, pounded or squeezed under great pressure into high strength parts known as forgings.

• The process is normally (but not always) performed hot by preheating the metal to a desired temperature before it is worked.

• It is important to note that the forging process is entirely different from the casting (or foundry) process

• A wide range of materials and alloys can be forged… from g y gA (Aluminum) to Z (Zirconium).

Forging Industry FactsForging Industry Facts

• In 2008, custom forgings accounted for nearly $11 billion of $ $sales in North America. An additional $3-$5 Billion in

catalog and captive sales would bring the industry total to the $14 - $16 billion range.

• Comprised of less than 500 forging operations in 38 states, Canada and Mexico. (see map on next slide)

• It is estimated that total energy usage is 1.5 to 2.0 Billion dollars

• Because the modern forging process is capital intensive, most forging plants are small businesses. 62% of Forging g g p g gIndustry Association Members have sales below $30 million. Only 8% have sales over $120 million.

Where are the forgers?Where are the forgers?

Forging Industry Educational & Research Foundation

MissionMission

• Established in 1961, Forging Industry Educational &Established in 1961, Forging Industry Educational & Research Foundation (FIERF) is a 501(c)(3) tax-exempt organization.

• Operating as a “supporting organization” to the Forging Industry Association, the Foundation’s mission is to support the forging industry through technical development and education

Research & DevelopmentResearch & Development

• Provide medium for forging and related industryProvide medium for forging and related industry collaborative research

• Fund technology developmentgy p

• Transfer technology to forging industry and users

Technical EducationTechnical Education

• Foster forging curriculum and experiential training inFoster forging curriculum and experiential training in university engineering departments

• Provide scholarships to encourage careers in the p gforging and related industries

FundraisingFundraising

• Seek support from government, industry andSeek support from government, industry and individual sources to grow programs to fulfill research and education goals

Past Research & DevelopmentPast Research & Development

• Competing Process StudiesCompeting Process Studies

• HotEye TM Inline Surface Inspection

• 3-D Temperature Profile of Forging Furnaces3 D Temperature Profile of Forging Furnaces

• Rapid Infrared Heating

Current ProjectsCurrent Projects

• Ultra High Magnetic Processing of AluminumUltra High Magnetic Processing of Aluminum

• Scale Free Reheating

• RSP – Rapid Solidification ProcessRSP Rapid Solidification Process

• Job Shop Energy

Ultra-High Magnetic Field Processing of AluminumAluminum

P i i i h d i ( i ) f l i ll i l l• Precipitation hardening (aging) of aluminum alloys requires long cycletimes accompanied by significant energy requirements.

• Aluminum is processed at low temperatures and waste heat recovery isnot economically viable.

• Ultra-high magnetic processing offers the possibility of reducing agingcycle time requirements from hours to minutes.

• Developing an unique technology will provide a significant competitiveadvantage and drive market and product innovation of NA forgers.

Project ParticipantsProject Participants

• Weber Metals

• Jorgensen

• Queen City Forge

• Scot Forge

• Inductoheat

• Rotek Inc.

• Aluminum Precision Products

• American Magnetics• American Magnetics

• Forging Industry Association

Scale Free Re-HeatingScale Free Re HeatingPrimary Objective

• To develop and test a scale free heating process and associated system design thatTo develop and test a scale free heating process and associated system design that reduces scale formation in steel reheating process

Approach

• Use of sub-stoichiometric combustion of natural gas to produce a non-oxidizing furnace atmosphere within the furnace with integration of a heat recovery system to optimize energy efficiency and economics of steel reheating furnaces.

Benefits

• Elimination of Scale formation during reheating

• Reduction in energy use, gy ,

• Significant production and maintenance cost advantages

• Improvement in steel quality

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Scale Free Re-HeatingScale Free Re Heating

Next Steps:Next Steps:

Conduct scale free heating tests on a pilot scale furnace.g p

Identify Alpha site and install pilot furnace

Project ParticipantsProject Participants• U.S. Department of Energy – EERE ITP Atmosphere Profile For Run 032008

First Addition of H2 and CO

% O2 % CO

• E3M, Inc

• ACL-NWO (Alchas, Inc.)

• Bloom Engineering40

50

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10

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14

16

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% CO2 NOx (ppm)

N2 OffCO @ 80% St i h

H2 AddedLeak in BypassUndetermined Flowg g

• SDI and other Steel Companies

• Air Products and Chemicals 10

20

30

2

4

6

8

Part

s Pe

r Mill

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%

N2 off and on duringissue with CO flow.

CO @ 80% Stoich

• Steel Manufacturers Association

• Forging Industry Association

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Rapid Solidification ProcessRapid Solidification Process

• Atomized metal (steel or super alloys) is sprayed onAtomized metal (steel or super alloys) is sprayed on the ceramic negative

• Material solidifies instantly and results in a density of y y99.7%, superior strength and toughness performance

• Opens the door to economic usage of high p g gtemperature alloys in mass production of tooling resulting in significant savings

Process Steps – Spray ProcessProcess Steps Spray Process

Opportunities & Challengespp g

• ENERGY Savings Potential:Internal 3D tooling features can be sprayed net or near net which- Internal 3D tooling features can be sprayed net or near net which

eliminated wire EDM or milling

- Tooling is hardened after spray. No separate heat treatment is required.

- Dies can be recycled and re-sprayed after use

• LEAD-TIME Potential:- Reduces tooling manufacturing from 4 weeks to 5 days

- Reduces cost for tooling by 30-70%

• CHALLENGES:-Significant investment required to commercialize technology (2,000,000)

Project ParticipantsProject Participants

• HHI-ForgingHHI Forging

• American Axle

• Hirschvogel IncHirschvogel Inc.

• RSP Tooling

• Forging Industry Assoc• Forging Industry Assoc

Job Shop EnergyJob Shop Energy

• Translate lean practice to energy management in aTranslate lean practice to energy management in a high mix – low volume environment• Characterize energy value stream in forges• Apply and implement EPHAST• Establish and implement “Best Practices”

A l f i d li t d t• Apply forging modeling to reduce energy cost

Project ParticipantsProject Participants

• FDMC – Forging Industry Association Department ofFDMC Forging Industry Association Department of Defense Manufacturing Consortium

• Scientific Forming Technologies Corp.g g p

• Case Western Reserve University

• Ohio State UniversityOhio State University

• Forging Industry Association

Technology Roadmap ProcessTechnology Roadmap Process

• Vision of the Future - 1996Vision of the Future 1996

• Technology Roadmap - 1997

2003 d• 2003 Update

• 2008 Update

Tech Roadmap ChallengesEnergy Issues

• Rising energy costs

• Process/production inefficiencies in the use of energy and lack of knowledge regarding efficient energy use

• Energy inefficiencies due to “boom time”

Tech Roadmap Activities to h llOvercome Challenges

• Optimize the heating of the materials to forge

• Partner with energy suppliers

• Encourage capital investment in new technology to reduce energy consumption

• Direct industry and government funds towards R&D in heating systems that can reduce energy costs

How might we work together?How might we work together?

Forging Industry contact infoForging Industry contact info

Office phone – 216.781.6260O ce p o e 6. 8 .6 60Web page – www.forging.org

Roy Hardy – Executive VP of FIAroy@forging orgroy@forging.org

Karen Lewis – Executive Director of FIERFkaren@forging orgkaren@forging.org

Carola Sekreter – Technical Director of FIAcarola@forging.orgcarola@forging.org