Honoring Practical Processing Science at TMS 2020
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https://doi.org/10.1007/s11837-020-04330-1 Ó 2020 This is a U.S. government work and not under copyright protection in the U.S.; foreign copyright protection may apply
PRACTICAL RESEARCH IN PROCESSING SCIENCE
Honoring Practical Processing Science at TMS 2020 ADAM PILCHAK
1,2
1.—Air Force Research Laboratory, Materials and Manufacturing Directorate (AFRL/ RXCM), Wright-Patterson Air Force Base, OH 45433, USA. 2.—e-mail: [email protected]
The art of extracting metals from their ores and then melting the metal to produce alloys that are cast into ingots, converted to billets, forged into shapes that are heat treated, quenched, stress relieved, machined, and subjected to surface treatments before being placed into service lives that may exceed 60 years in the harsh environment of a gas turbine engine is nothing short of miraculous. Consider further that each step may consist of many individual steps. Some open die forging operations, for example, may consist of more than 100 combinations of rotations, translations, upsets/draws, repositioning the part, and reheating. Furnace temperatures, heating and cooling rates and time at temperature must be controlled and some demanding applications must be quenched within seconds to make their solution heat treatments effective. There are so many different alloys being forged into a wide variety of shapes and section thicknesses for many different industries (automotive, aerospace, defense, construction, medical/ biomedical). Coupled with the complexity of these operations, it is no surprise that Edisonian-based approaches to optimizing forging practices could quickly bankrupt a supplier, and reduction of scientific knowledge gained in the laboratory to practice is difficult given all the potential sources for variability. It was clear early to those in the industry that practical methods and models would be needed to help guide process development and this is exactly what a small group of scientists and engineers at Battelle Memorial Institute set out to work on in the late 1970s. With combined expertise in mechanics, metallurgy, processing science, and computational methods, Taylan Altan, Soo-Ik Oh, Wei Tsu Wu, and Lee Semiatin were constantly advancing the state of Adam Pilchak and John Rotella are guest editors for the Titanium Committee, Shaping and Forming Committee, and ICME Committee of TMS, and coordinated the topic Practical Research in Processing Science in this issue. (Received August 6, 2020; accepted August 11, 2020)
the art in the processing of metallic materials; often before the rest of the world was ready for it. For example, their team was the prime contractor for the very first Air Force Materials Lab Processing Science Program. During this program, the team developed (what we call now) a foundational engineering problem using integrated computational materials engineering (ICME) to optimize the process for creating a dual-microstructure/dual-property Ti-6Al-2Sn-4Zr-2Mo disk—and they did this 25 years before the widespread adoption of ICME in ou
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