CEFT – Capabilities (incomplete)

1. CEFT – Capabilities (incomplete) Long term and short term

2. OSU Facilities and Resources • Forging Equipment • Heating Equipment • Spray Equipment • In-process Inspection and monitoring • Tools for off-line characterizing

3. Mechanical Press Details Type: Ajax Pitman, Year 1950, Rebuilt in 2000 With new electricals and controls, New Crank, New Bushings Brass, New 3 pass fixture, Condition: Was in operation in 2001 Tonnage: 1300 tons Weight: 165,000 lbs Motor: > 5 HP, 1200 rpm, 93 amps Cycle: 70 strokes per minute Die Space: 44” x 33”, Floor Space: 11’ X 9’ 4” Height: 16’3” (16’ above ground) Shut height: 21.75”, Stroke: 10” Wedge: 1.625”, Hydraulic Kick Expected to be Operational by June 2003

4. Being refurbished by Erie Press Systems • Fitted with • New MCU • New Operatror Panel • New Pneumatic and Lube System • New controls, DAQ • Angstrom Tonnage monitors • Inkind donation from Erie ~ $95,000

5. Induction Heater for 1300 Ton Press • 250 KW heater power, 356 KVA, 250 KW • Purchased and donated in part by Inter-power Inc., Michigan (in kind assistance ~ $64,000) • Can heat upto 2” X 6” billet • Through put 4 lb/min

6. Lubrication System • Donated by CMT (~ $90,000) • Airless and Air Assisted Systems • Electrically operated Positive Displacement pump • Totally adjustable flow rates with +/- 1% flow accuracy • Viscosities up to 200,000 cps • Pressures up to 3000 psi • PC control with data logging • Intergraded to operate with mix/dilution station and nozzle movers

7. Pump Mixer / Diluter

8. Gleeble 3800 • 20 tons of static force in compression or 10 tons in tension • Displacement rates as fast as 2000mm/second • LVDT transducers, load cells, or non-contact laser extensometry provide feedback for motion and load control • Fully integrated with LabView • Expected Fall 2003

9. Hydraulic Press • Used for small scale testing • Type: Interlakan • Tonnage: 100 tons / 150 ton blank holder • Max speed: .75” / sec • Program Controlled ram motion

10. Induction heater for Hydraulic Press • Induction heater from Interpower • 25 KW power supply • Maximum billet size 1” diameter • Heater equipped with a loading magazine and a pushrod • Donated / loaned by Interpower

11. Hydraulic Press Temperature Measurement Induction Heater Initial Billet Placement of Hot Billet on Dies Forging of Hot Billet at Room Temperature Hot Billet on Dies

12. Other Facilities @ CEFT Wear Characterization: • TEM: Philips CM200, Philips CM300 Ultra-Twin FEG, Philips EM400T, Philips Tecnai TF20, FEI Dual Beam 235 FIB • SEM: FEI Sirion • X-ray diffractometer: Philips XRG3000, Scintag XDS2000, Philips XRG3000 Die Thermal Mapping: Thermal Cam (FLIR) Part Surface Characterization: Hoteye (loaned by OGT Technology) Die Surface Characterization: Mitusubishi Laser CMM (CIS)

13. Laser Measurements – 3D Scanner

14. Details of Press, Fixturing and Dies for Hydraulic Press

15. Hydraulic Press Layout

16. Some dies being tested

17. Instrumented Dies

18. Die Geometry and Associated Equipment • 100 mm (4 inches) in diameter / 50 mm (2 inches) in height • Various heat treat grades of H-13 tested todate • The dies were heated by 500 Watts electric Band heaters manufactured by Chromalox Inc., Pittsburgh, PA. • Die temperatures were 175°C (350 F) - Temperature was checked by an OMEGA touch probe temperature sensor (K type). • The dies were placed on fixtures consisting of two oil-hardened steel plates separated by steel blocks to ensure a passage for thermocouple wires.

19. Other Tests: Multi-scale Tests Spike Test for Closed Die Lubrication Ring Test for Lubrication Evaluation Product Specific Tests (on 1300 ton press)

20. Research needs – In-kind contribution needs • Die material suppliers • Machining and heat treat suppliers • Coating and surface modification vendors • Forging consumable suppliers • Forgers • Post forging analysis