CHTE Selected For Two Major Awards To Advance The Knowledge Base In Heat Treating (July 30, 2001)

The Center for Heat Treating Excellence (CHTE) has been selected to receive two major awards from the Department of Energy, Office of Industrial Technologies (Supporting Industries Program). Negotiations are under way for the procurement of these cooperative agreements, which are targeted to commence in September 2001.

The two industry-university collaborative research programs involve three universities and over a dozen metals processing companies.

The budget for these two projects which span four years, total over $5.8 million --- half will be supplied by DOE and half by the industry and university partners. A brief abstract for each project is given below.

An Integrated Heat Treatment Model for Aluminum Castings

The proposed program of research will develop, verify and market an integrated system of software, databases, and design rules to enable quantitative prediction and optimization of the heat treatment of aluminum castings to increase quality, increase productivity, reduce heat treatment cycle times and reduce energy consumption. One of our industrial partners demonstrated, empirically, that the solutionizing time for a cast aluminum alloy could be reduced from 12 to 2 hours with no loss of quality or properties. This magnitude of heat treatment cycle time reduction will result in increased productivity and/or reduced energy consumption of greater than 50%. Validated databases for multi-component alloys and predictive models will enable comparable results to be achieved for a wide range of alloys and applications.

The software will predict the thermal cycle in critical locations of individual components in a furnace, the evolution of microstructure, and the attainment of properties in heat treated aluminum alloy castings. The model will take into account the prior casting process and the specific composition of the component. The heat treatment simulation modules will be designed to be used in conjunction with software packages for simulation of the casting process. The system will be built upon a quantitative understanding of the kinetics of microstructure evolution in complex multi-component alloys, on a quantitative understanding of the interdependence of microstructure and properties, on validated kinetic and thermodynamic databases, and validated quantitative models.

Detailed understanding of the evolution of microstructure during the heat treatment together with accurate databases of experimentally determined thermodynamic and kinetic parameters will support quantitative predictive models for binary alloys. The research phases of this program will focus on gaps in understanding and data on multicomponent alloys --- to expand our understanding and ability to predict quantitatively for complex, commercially important alloys (i) the kinetics of microstructure evolution and (ii) the relation of microstructure to strength, ductility, and fatigue properties. The research phases will be concurrent and iterative with development of the software modules. As the modules are developed and validated, their utility will be demonstrated as we apply the modules to meet three objectives: (i) reduced reheating, (ii) alloy design for faster response to heat treatment, and (iii) higher productivity.

This R & D program is directly responsive to the research needs designated as top priority by industry leaders at strategic workshops sponsored by the Department of Energy Office of Industrial Technology (DOE-OIT). Consider, as example, this statement of research needs in the Report of the Heat Treating Technology Roadmap Workshop, Chapter 4; Processes and Materials (February 6-7, 1997).

One of the most important research needs identified was the development of integrated process models. Heat treating today is viewed as an experience-based art. However, by the year 2020 it must function in a scientific, predictive environment, where processes are truly understood and capable of being simulated.

The research team consists of Professors Kevin Rong and Rick Sisson (WPI), and Professors John Morral and Hal Brody (U of Conn), along with their colleagues and graduate students. CHTE partner industries will be involved in the program of research and will be active participants.

The total cost of the proposed program over a period of four years is: $3,006,614. The funding from DOE is a total of $1,502,770 for a period of four years. The non-federal cost share commitments total $1,503,844 over a period of four years. The non-federal cost share is made of industrial support and university cost sharing.

Materials and Process Design for High-Temperature Carburizing: integrating processing and performance

The program of research applies a new computational materials design approach to integrate process and material optimization for fast high-temperature carburizing and the creation of a new class of thermally-sTABLE CLASS="format" case-hardened ultra-durable tool and die steels with broad applications in manufacturing processes. The research seeks to increase energy efficiency, reduce waste, and increase the productivity of the domestic Supporting Industries. The optimization and control of high-temperature carburizing responds to Performance Targets for Productivity and Quality in the Heat Treating Technology Roadmap, calling for reduced process cycle times by 50% or more, and the achievement of zero distortion and maximum uniformity in heat treated parts. The proposed program directly responds to identified high-priority Research Needs in (a) High-Temperature Processes, specifically the development of high-temperature carburizing above 1010C, and (b) Heat-TreaTABLE CLASS="format" Materials, specifically the development of alloys optimized for high-temperature carburizing, and which resist grain coarsening at 2000F. The latter also respond to Strategic Goals of the Forging Industry Technology Roadmap in Tooling and Materials. This specifically responds to identified Research Needs in Improved Die Materials with longer life and reduced wear. Industry of the Future sectors benefiting from this research in reduced scrap and enhanced productivity include steel, aluminum and metal casting, through applications of the new ultra-durable die materials in the forging and forming of steel and aluminum, and the die-casting of aluminum.

The research team consists of Professor Greg Olson (Northwestern University) and Professor Diran Apelian (WPI) along with their colleagues and graduate students. CHTE partner industries will be involved in the research program and will be active participants.

The total cost of the proposed program over a period of four years is: $2,842,428. The funding sought from DOE is a total of $1,420,428 for a period of four years. The non-federal cost share commitments total $1,422,000 over a period of four years.

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