Preliminary Study on the Capability of the Novel Near Solidus Forming (NSF) Technology to Manufacture Complex Steel Components

Plata, Gorka; Lozares, Jokin; Sanchez, Andrea Valeria Gomez; Hurtado, I.; Slater, Carl

doi:10.3390/ma13204682

Cited by 6 publications

(4 citation statements)

References 23 publications

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“…This suggests that to ensure good chemical bonding, the material could be maintained under pressure for a certain period just after the process is finished to increase the pressurized contact time at elevated temperatures and, consequently, promote larger diffusions. This also agrees with the results observed in [16], where, even if it was a single material, the generated folds joined back again at the end of the NSF process. This could also suggest that the observed folds with these two materials could be closed if the entire cavity is filled.…”

Section: Discussionsupporting

confidence: 91%

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A Preliminary Study on the Quality of Joining AISI 316 and AISI 3415 Steel by the near Solidus Forming Process

Plata,

Gordo-Burgoa,

Lozares

et al. 2023

Metals

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In this study, the Near Solidus Forming (NSF) process, which falls under the umbrella of semi-solid processes, was utilized to coforge an AISI 316 tube and an AISI 3415 rod into an as-forged valve geometry. The billet used for the process was kept as large as possible to increase the contact surface area between the two materials. The process was carried out at 1360 °C in a single stroke, almost completely filling the geometry. No joining was observed in areas where low strains were expected, but in regions with medium to high strains, cross-diffusion of 2–7 μm was observed. The presence of small oxide particles was also observed in the joint due to the bimetallic billet shape.

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Section: Discussionsupporting

confidence: 91%

“…However, in addition to these benefits, there are many other advantages that can be obtained with this process due to the behavior of the material under these conditions [16]. One of these benefits, which has recently been evaluated, is the ability of the process to co-forge dissimilar materials to produce a complex component.…”

Section: Introductionmentioning

confidence: 99%

A Preliminary Study on the Quality of Joining AISI 316 and AISI 3415 Steel by the near Solidus Forming Process

Plata,

Gordo-Burgoa,

Lozares

et al. 2023

Metals

Self Cite

View full text Add to dashboard Cite

show abstract

“…The process is done either at room or high temperature based on the material and the desired properties of the components. In particular, Near solidus Forming (NSF) process is referred to the one developed critically close to the solid temperature and it is gaining popularity due to its good physical properties, low manufacturing cost and material waste compared to traditional hot forging process [1,2]. Although gaining popularity, the process is not still fully developed, and it is not clear how the physics behind the NSF develops [1].…”

Section: Introductionmentioning

confidence: 99%

“…In particular, Near solidus Forming (NSF) process is referred to the one developed critically close to the solid temperature and it is gaining popularity due to its good physical properties, low manufacturing cost and material waste compared to traditional hot forging process [1,2]. Although gaining popularity, the process is not still fully developed, and it is not clear how the physics behind the NSF develops [1]. This is due to the complex behavior of the material at such a high temperature.…”

Section: Introductionmentioning

confidence: 99%

Digital twin development for the sensitivity analysis of near solidus forming process

MUHAMMAD

2023

Materials Research Proceedings

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Abstract. Near Solidus Forming (NSF) process, performed at semi-solid material state is gaining popularity due to its good physical properties, low manufacturing cost and material waste. Although the process possesses many advantages over traditional hot forging, the nature of the process itself is very complex and due to this the researcher struggles to identify the material behavior at NSF conditions. Especially the material model in this condition has not been stated clearly before and therefore it is important to develop a reliable digital twin (DT) strategy which can validate the material model efficiently. Therefore, the objective of this work is to investigate the influence of all DT parameters like billet material and dimensions, billet and dies temperature, heat transfer coefficient, emissivity, ambient temperature, and friction coefficient, in two industrial components such as H spindle and R spindle. The Taguchi Design of Experiments (DOE) approach combined with numerical simulation in FORGE NxT® is employed to develop the sensitivity analysis of the process. The impact of all parameters in the DT are evaluated in terms of die filling and forming forces, and its importance in the material model is studied. Results show that the newly developed approach proposed a novel optimum NSF-DT calibration strategy for material-model validation. Which can be used to develop an accurate model of the NSF process at the laboratory and industrial scale

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Characterization of the heat transfer coefficient at near solidus forming condition using columnar pressing test

Sajjad,

Agirre,

Plata

et al. 2024

Int J Adv Manuf Technol

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This study addresses the significant gap in the literature regarding the heat transfer coefficient (HTC) under near-solidus forming (NSF) conditions, where materials are shaped close to their solidus state, presenting complex behaviour compared to traditional hot forming processes. Despite the pivotal role of heat transfer in developing a reliable material model for the digital twin (DT), limited data exist particularly regarding HTC characterization at NSF. Additionally, testing methodologies suitable for the high-temperature conditions, crucial for NSF processes, have not been adequately addressed. To fill this gap, this study aims to characterize HTC under NSF conditions using a columnar pressing test. The test was conducted at three different temperatures such as 1250, 1300, and 1360 °C and two different pressures, 2 and 8 MPa. During the test, temperature data was collected at the centre of the sample using a k-type thermocouple. Furthermore, the DT of the pressing test was developed and the three-dimensional finite element model of 42CrMo4 steel was constructed using FORGE NxT® 4.0 FEM software. The simulations were performed with varying HTC values to replicate the experimental test data. Inverse modelling techniques were then applied to compare experimental and simulated data, enabling the characterization and optimization of HTC values under NSF testing conditions. The results demonstrated that HTC in the NSF process is primary impacted by the forming pressure, whereas temperature change showed no variation at the studied ranges. The HTC value of 500 W/m2K and 800 W/m2K was identified at 2 MPa and 8 MPa, respectively. The conclusion of this study aims for a better understanding of heat transfer phenomena in NSF processes, enhancing the reliability of DT for industrial applications.

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Preliminary Study on the Capability of the Novel Near Solidus Forming (NSF) Technology to Manufacture Complex Steel Components

Cited by 6 publications

References 23 publications

A Preliminary Study on the Quality of Joining AISI 316 and AISI 3415 Steel by the near Solidus Forming Process

A Preliminary Study on the Quality of Joining AISI 316 and AISI 3415 Steel by the near Solidus Forming Process

Digital twin development for the sensitivity analysis of near solidus forming process

Characterization of the heat transfer coefficient at near solidus forming condition using columnar pressing test

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