Speakers and Presentation Information

Precision Forging Gears

Forging and control of forging variables to produce the highest precision, quality product is presented.  The application and limitation to gear blanks is also discussed. 

J. Richard (Dick) Douglas is a principal of the Metalworking Consultant Group LLC, a company he started after leaving Eaton Corporation in 1998.  Dick has spent most of his career working in the forging industry, much of it devoted to development of techniques for precision forging.  Dick is a fellow of ASM.

Workability Characterization, and its Relationship to Metal Flow and Defect Formation during Forging Processes

Workability characterization mainly focuses on determining the ability of a material to resist fracture during bulk metalforming processes.  A variety of test methods and sample geometries have been used for this characterization, and several of these will be discussed.  The more important aspect of workability is relating a particular test method and the results to an actual deformation process used to produce a component.  These considerations relate to sequence design for multi-step forging processes and preform design for precision forging processes.  Examples of defect formation, metal flow that leads to or avoided such defects, and relation to workability characterization will be discussed.

Dr. B. Lynn Ferguson is President and founder of Deformation Control Technology (DCT), Inc.  He has a Ph.D. in Materials Engineering from Drexel University. His areas of expertise include metallurgical engineering, powder metallurgy, forging preform design, structure/property relations, and finite element analysis.

Rapid Production Forging Dies Using RSP

The RSP process is capable of producing high quality complex forging dies that can increase tool life yet still save time and money.  It allows a forger to make prototype forgings and when approved, immediately start running production.  The tools have proven capable of increasing tool life 2 to 3 times standard H13 tools.

James Knirsch is president of RSP Tooling.  He has had over 20 years experience in the tooling industry and has been running RSP for five years.  He has a degree in engineering and an MBA.

Texture Measurement and Analysis during Hot Rolling of Titanium Alloys

Challenges associated with measuring texture for alpha/beta titanium alloys will be discussed and illustrated for the process of hot rolling of Ti-6Al-4V.  An overview of texture measurement techniques with a focus on X-ray diffraction and electron backscatter diffraction will be presented.  The correlation between texture and the mechanical properties of metals will also be summarized. 

Dr. Ayman Salem is a staff member in the Metals Processing Group, Materials and Manufacturing Directorate, Air Force Research Laboratory, Wright-Patterson Air Force Base, Ohio.  Dr. Salem earned his B.S. and M.S. degrees in Mechanical Engineering from Cairo University and Ph.D. in Materials Science and Engineering from Drexel University.  His work focuses on metal forming, texture formation, mechanical properties of materials, crystal-plasticity analysis, and novel deformation processes.

Making Fat Things Thin, or Basics of Wire Drawing

The fundamental and practical aspects of wire drawing will be presented, illustrating how common principles apply to all metals.  This would include i) Drawing mechanics, ii) Quality issues, iii) Wire Testing, iv) Modeling, and v) Practical problems.

Dr. Daniel Hennessy is a metallurgical engineer with General Electric Company, and has wide experience in the area of tungsten manufacturing and processing within the United States, Europe and China.   At GE Lighting in Cleveland, Dan has been responsible for the design and implementation of many new techniques for the manufacture of tungsten wire that have helped GE to remain competitive in a global market place. As a direct result of his experience he has managed a number of major projects for GE and trained entire businesses in the process of tungsten and molybdenum wire manufacture. In addition to his refractory metal experiences involving powder metallurgy, induction heating, rolling, swaging and wire drawing, Dan has first hand expertise in the melting, casting, rolling, and drawing of copper and aluminum wire.  Dan holds a Ph.D. in metallurgical engineering from the University of Illinois and a B.S. in metallurgical engineering from the University of Notre Dame. He has been awarded a Six-Sigma Green belt at GE, plus managerial awards on four occasions. During his career he has contributed to ASM at the local level as Chairman of both the Cleveland and Fort Wayne chapters, and to the Wire Association International by writing a section for their “Non Ferrous Wire Handbook”.

Thermo-Mechanical Processing of Metals for High Temperature Applications

This talk discusses practical considerations for the application of Extrusion and Rotary Forging to "difficult" materials.  Using a simple point of view, extrusion and rotary forging accomplish the same goal.  In practice they are very different and those differences lead to unique outcomes.

Brad Lemon is the Process Engineering Manager for H.C. Starck in Coldwater, Michigan.  Previous to his management responsibility he was responsible for the development of GFM forging practices and has worked closely with extrusion throughout his 7 year career at H.C. Starck's Coldwater, Michigan site.  Brad was educated to the Bachelor's level in Materials Science and Engineering at the University of Michigan.

 Superplastic Forming (SPF) of Titanium Components at Goodrich

A description of superplastic forming of titanium and the various components manufactured under this technique at the Goodrich Corporation.

Dr. Robert Bianco is the R&D Manager of the Advanced Materials Applications, Materials & Simulation Technical Center, Goodrich Corporation.  Bob received his Ph.D. M.S., and B.S. in Metallurgical Engineering from The Ohio State University.  He worked as Senior Engineer in the Advanced Materials Department at Westinghouse's Bettis Atomic Power Laboratory from 1992 to 1997. 

Hydrostatic Extrusion – Effects of Stress State on Flow, Fracture, and Deformation Processing of Materials

In order to cover aspects related to hydrostatic extrusion, the effects of changes in stress state on the flow and fracture of conventional and advanced structural materials will first be reviewed.  Significant beneficial effects of changes in stress state (e.g. superimposed hydrostatic pressure) on the flow and fracture behavior have been documented and these will be reviewed in the light of their relevance to hydrostatic extrusion.  Some examples of materials systems successfully processed via hydrostatic extrusion will be provided, along with property changes related to such processing.

Prof. John J. Lewandowski is the Leonard Case Jr. Professor of Materials Science and Engineering, and Director of the Mechanical Characterization Facility, Case Western Reserve University.  John received his B.S., M.E., and Ph.D. in Metallurgical Engineering and Materials Science at Carnegie Mellon University where he was a Hertz Foundation Fellow.   He was elected Fellow of ASM in 1995 and is past Chair of the ASM/TMS Joint Composites Committee.  His publications and presentations number in excess of 200 and 475, respectively, and are primarily in the areas of processing/structure/property relationships in ferrous and non-ferrous engineering materials; the effects of superposed pressure on deformation and fracture; fatigue and fracture of intermetallics and composites, bulk metallic glass, and layered/laminated materials; deformation processing; blast-resistant materials; and engineered materials systems.

Computer Simulation of Metalworking Processes

Simulation of metalworking processes using the finite element method is a mature technology, at least from the mathematical side.  There are several widely used software packages that are used routinely to simulate hot and cold forging, extrusion, drawing and rolling processes.  This presentation will address the data needs for these process simulations, simulation accuracy, and interpretation of results.  In particular, the linkage between reality and simulation will be explored, with reality focusing on microstructural response.

Dr. Zhichao (Charlie) Li, Deformation Control Technology (DCT), Inc. has a Ph.D. in Mechanical Engineering from Wright State University, and Bachelor and Master Degrees in metal forming from the Harbin Institute of Technology. He has a strong background in computer analysis of metal forming and heat treat processes.

Solving Metalworking Problems Using Black Belt Methods

Ed Longenberger is employed at Brush Wellman and has been in the R&D of Cu-Be alloys for over 20 years.

Design and Manufacture of Rolling Mills

The talk focuses on the design and manufacture of rolling mills.

Tad Sendzimir is president and CEO of T. Sendzimir, Inc. The company is best known for its cold reversing steel mills designed to roll stainless and other hard to roll or exotic materials.  Founded in the early 1950's by the Polish inventor, Tadeusz Sendzimir (born 1894), the business started in association with ARMCO as the "Armzen" company; later changing its name to T. Sendzimir, Inc.  The first product lines were for hot-dipped galvanizing lines, for which the company's founder was the inventor and patent holder.  The company then moved into cluster mill technology, eventually becoming known worldwide for its cold reversing steel mills designed to roll stainless and other hard-to-roll exotic materials.  In recent years, the development of the Z-High® mill has led to the use of high-reduction Z-High inserts at the entry end of A/P process lines.

 Technological Advances in the Design Tools, Alloys, and Processing of High Strength, Large Monolithic, Aluminum Forgings

Over the past decade, monumental advances have occurred in design software, alloy development, and processing techniques in order to produce large "monolithic" high strength aluminum alloy forgings for the aerospace and commercial industry with heat treat sections up to 12" thick.  This includes the use of high speed computers mirrored with proprietary developed software, a new generation aluminum alloy 7085, and specialized forging techniques.

Dustin Bush is a Staff Metallurgical Applications Engineer, Alcoa Forged Products - Aerospace.  He has worked at Alcoa for 8 years.  Dustin has worked within the forging metallurgical group for his first 7 years, and recently became the Staff Alcoa Forgings Application Engineer, responsible for forging alloy and processing R&D, as well as field applications, reporting directly to the Alcoa Forgings R&D Manager.  He holds the degrees of B.S. in Metallurgy from The Ohio State University and an M.S. in Materials Science and Engineering from Case Western Reserve University.