Casting & Forging

1. Casting & Forging Stephen Conner 23 July 2014

2. Casting & Forging Aviation Forging and Casting Assistance Team (AFCAT) Steve Connor AFCAT Program Manager Walker George AFCAT Application Engineer Keith Sturgill AFCAT Application Engineer

3. Warfighter Relevance • Unfilled orders • Preventing cancelled contracts • Military aviation requirements present unique challenges

4. Sustainment Horizon • Problem: The Perfect Storm • Small quantity orders • Short lead times • Infrequent buys • Labor intensive RFQ System • No tooling • Objective: • A more innovative approach • Responsive to industry concerns • Utilization of industry expertise • Sharing of knowledge

5. Weapons Systems Sustainment • Castings and forgings represent about 4% of DLA solicitations but 15-20% of backorders over 180 days • Forgings/castings is hindered by • Lost tooling • Fragmented supply chains • Diminishing supply base • Inadequate procurement data • Hog it out?

6. First Article Testing (FAT) • FAT Impact • Effects of draft on part dimensions • Sharing lessons-learned • FAT punch list examples

7. FAT Submission Punch List • Material certification sheets (chemical analysis/mechanical/physical properties with traceability to mill) • All other certifications: including finish requirements (i.e. plating, heat treatment, welding, inspecting, anodize, painting, NDI, etc.) utilized in the manufacture of the FAT item(s). • Traceability certifications of all purchased hardware and components used in an assembly • A copy of the purchase order certifying the process accomplished at other than contractor facility shall also be included. • Process Operation documentation • Traveler Documents with quality stamps • In-process inspections performed with inspection data included • Sub-vendor certifications (welding, heat treat, NDT, Plating) *Proof of ISO or equivalent certification • Quality Manual (ISO 9000 or equivalent)

8. FAT punch list continued • Equipment Calibration Dates • If not specified on the drawing, the datum point selected for all measurements • Notes regarding drawing draft allowances against nominal dimensions • Actual Measurement data and drawing tolerances • Any special processing notes to be considered (bar code label versus laser etching due to part geometry) • Basic Contract Copy (very important that it be included in the documentation package) • Any Contract Modifications (if applicable) • Wide Area Workflow (WAWF) Receiving Report with "Inspected" Endorsement by DCMA (Origin Inspection) • Contract CLIN 9906 FAT WAWF or DD-250, Inspected by DCMA QAR • Documentation of domestic materials, particularly for inserts and fasteners. • Documentation of Approved bearing and required stake tools

9. Source Approval Requests (SAR) • AFCAT assistance with Casting and Forging SAR submissions • Recent success stories • Reverse Engineering opportunities

10. Casting/Forging Clauses • “A metal casting process was identified as a means to manufacture this item. Tooling is required to produce a casting. For sourcing, tooling, materials or other information, please contact the appropriate assistance team: (Aviation, C&E Supply Chains) DSCR.afcat@dla.mil ; (Land & Maritime Supply Chains) DSCC.cast.forge@dla.mil” • “A forging process was identified as a means to manufacture this item. Tooling is required to produce a forging. For sourcing, tooling, materials or other information, please contact the appropriate assistance team: (Aviation, C&E Supply Chains) DSCR.afcat@dla.mil ;(Land & Maritime Supply Chains) DSCC.cast.forge@dla.mil”

11. Future Initiatives • Economic Order Quantity opportunities • Casting/Forging groupings • Expanded ESA casting/forging training • Modification of casting/forging clauses

12. The American Metalcasting Consortium Engineering Team • Metalcasting consultants totaling 150+ years of casting experience • TDP review • 339 assistance • Access to capable foundries and post-process suppliers • Cast-conversions • Technical assistance to foundries • Proliferate advanced technology Dick Farrara Bennington, VT Jack Church Bloomington, MN Gary Burrow Billings, MT Keith Sturgill Richmond, VA Dave Poweleit Barrington, IL Jenny Swygert Charleston, SC

13. The Forging Defense Manufacturing Consortium Team Richard Farrara N. Bennington, VT Walker George Richmond, VA Prabir Chaudhury Phoenix, AZ Jon Tirpak Charleston, SC Chris Bergner Charleston, SC http://fdmc.scra.org/

14. Where to get help AFCAT Assistance Requests: DSCR.AFCAT@dla.mil or Stephen.Connor@dla.mil 804-279-1750 Locate Forging Dies National Forging Tooling Database (NFTD) available through IHS Haystack Gold http://aero-defense.ihs.com/products/procurement/haystack-logistics/ Locate Casting Patterns Available through the Non Ferrous Foundry Society (NFFS) http://www.defensetooling.com/ American Metalcasting Consortium (AMC) http://amc.scra.org/ Forging Defense Manufacturing Consortium (FDMC) http://fdmc.scra.org/

15. Questions/Concerns

16. DEFENSE LOGISTICS AGENCY AMERICA’S COMBAT LOGISTICS SUPPORT AGENCY WARFIGHTER SUPPORT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT