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FIA Quick Read Newsletter

June 29, 2011

TopFoundation Thanks Nucor Steel, Walker Forge & Rotek Incorporated!

FIERF is pleased to announce three FIA Members who have pledged to support the Foundation as Anvil Society Members:


Nucor Steel and Walker Forge have become important partners as Silver Anvil Members.  Rotek Incorporated has become a Bronze Anvil Society Member.


It is because of the support FIERF receives from the industry that programs such as Finkl Scholarships, student outreach (see related article) and research projects are funded. 


The Foundation is indebted to all our Gold, Silver and Bronze Anvil Society Members.  Click here  


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Senator Visits Ellwood Quality Steel

Ellwood Quality Steels is the largest of Ellwood Group, Inc.'s seven divisions.  EGI divisions represent FIA open die, closed die and supplier membership.  Recently EQS hosted Pennsylvania Senator Pat Toomey (link to article), who was impressed not only with the operation, but also with the initiative and drive of EQS's staff.  It was a great opportunity for a FIA member to communicate the message of "do no further harm" and reinforce the need for less government regulations.  Special thanks to David Barensfeld for his impressive company and for standing tall for the industry.


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Foundation Thanks Nucor Steel, Walker Forge & Rotek Incorporated!
Senator Visits Ellwood Quality Steels
FIA Lobby Day 2011
International Forgemasters Meeting Registration Opens - Early Bird Expires June 30
Attention Suppliers to the Forging Industry ......New IFM Promotional Opportunity
Theory & Applications of Press Forging and Die Design - September
Growing Student Outreach with ASM Partnerships
2011 Forging Capability Guide Released
Fatigue Life Comparison
FIERF Seeking Additional Funding For Industry Research
Technical Conference Papers Available to Members
2011 Defense Logistics Conference & Exhibition

FIA Lobby Day 2011

Beginning in 2004 with the first annual FIA Lobby Day, the FIA has undertaken a concentrated effort to help the industry understand how decisions are made by Congress and the Executive branch, to educate Congress and regulatory agencies about forging and the forging industry, and to build a capability to influence those decisions when necessary and appropriate. 


FIA's 8th Annual Lobby Day was held on June 14 and it was the biggest ever, with attendance by 26 representatives of the industry from all over the U.S.  Meetings were held with the offices of 13 Senators, 21 Representatives, leadership offices in the U.S. House of Representatives, and staff from the House and Senate Small Business Committees to discuss issues of concern to the industry.


FIA produced a short video to introduce Congressional Members and their staff to the Forging Industry, and it was very well received (Click here) to view video.


Key issues at this year's Lobby Day included:


  The need for adequate supplies of affordable energy, including natural gas, because forging is an

   energy-intensive process.

  Concern over continued U.S. EPA regulations of greenhouse gas emissions from natural gas.

  The growing burden of over-regulation on the competitiveness of the U.S. forging industry.

  Support for comprehensive tax reform that will improve U.S. manufacturers' global


 Capital Building


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International Forgemasters Meeting Registration Opens - Early Bird Expires June 30

The 18th International Forgemasters Meeting (IFM) will be held in the United States, September 12-15, 2011. This will be the first time IFM has been held in the USA since 1994. The Meeting will be held at the Omni William Penn Hotel in Downtown Pittsburgh, and will include 80 technical papers from 12 nations covering everything from steelmaking and refining to simulation and modeling. In addition, 10 country/regional market overviews will be presented from the world's leading open die producing nations. Also occurring during the meeting will be an exhibition featuring 35 forging supplier companies from all over the globe displaying the latest technology and improvements in their respective areas. Two plant tour options will be offered that will take attendees through five forging and supplier companies.


Don't miss this unique opportunity to meet and greet top level forging and supplier executives from across the globe! See www.IFM2011.com for registration information or request a printed brochure by calling FIA at 216-781-6260.


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Attention Suppliers to the Forging Industry ...  New IFM Promotional Opportunity

Want to reach the expected 400-500 attendees of IFM 2011 right where they live? Then consider advertising in the 18th International Forgemasters Meeting (IFM) Official Meeting Program to be distributed to all attendees on-site in Pittsburgh, September 12-15, 2011. The booklet will serve as show guide and reference manual for the entire meeting, and will likely be kept as a reference manual... keeping your ad in front of your prospects long after the meeting.

Ads are available in all sizes and color options to fit your marketing budget.Click Here
to see these options, pricing and ad reservation information.  


There are a limited number of premium advertising spots available on a first-come, first served basis. 


We must have all materials in by July 29th, so don't delay.  For more information on the 18th IFM, see www.ifm2011.com  


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Theory & Applications of Press Forging and Die Design - September 26-29, 2011 - Cleveland

This is a 4-day program providing forging-specific information regarding the application of various types of presses as well as guidelines for designing tooling for forging and trimming.  Taught by experienced academic and industry experts, the specific goals of the course are:

         Broaden knowledge about press forging

         Provide a basis for objective press selection

         Furnish useful tool design guidelines

         Compare approaches to press automation

         Review guidelines for matching the press to the part in terms of size and operational features


This program is only offered every two years. The next presentation is scheduled for 2013. If you are interested in the attending, it is suggested that you register early.


(Click here) to view/print complete program and registration form.


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Growing Student Outreach with ASM Partnerships

Materials Camps:


FIERF is partnering with ASM International to participate in the Teachers Materials Camp on June 28 and a Student Camp July 25-29.  Both Camps will be held in the Cleveland area.  The intent is to learn more about the camps this year and to sponsor or co-sponsor camps in the future. 

If you are interested to observe at a Cleveland Camp, learn more about the camps in general, or are interested to participate in a camp in your local area please contact Karen at [email protected] or 216.781.6260.


Material Science & Technology 2011 Conference and Exhibition:


The Foundation will also have a booth in the Career Pavilion at the Material Science and Technology Conference & Exhibition October 16-20 in Columbus, Ohio.  FIERF will be a sponsor of a student networking reception and be able to post job openings (both electronically and in hard copy) for FIA Member Companies.  Last year 800 students attended the show with the same number expected to participate in October.


Carola Sekreter, FIA Technical Director will be making a presentation on careers in the forging industry for students.


If you job openings you would like to post for students and/or professionals, would like to visit the show, or if you would like more information, please contact Karen at [email protected] or 216.781.6260.


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2011 Forging Capability Guide Released

FIA is pleased to announce availability of the new 2011 Forging Capability Guide (FCG). The fully searchable CD contains location and facilities listings of all FIA Member custom forge shops, forging market and process descriptions and graphics, and a "Special Capabilities" column that further defines forging company capabilities, making it easier for customers to select prospective sources.


The primary purpose of this Guide is to promote the capabilities of FIA members and the forging process to forging customers and prospects. It will be distributed to thousands of customers and prospects worldwide. Copies of the 2011 Forging Capability Guide are available to FIA members for $25.00 each and to FIA non-member forging and supplier companies at $100.00 each (postage and handling included). Click Here to order or contact FIA at [email protected].


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Fatigue Life Comparison between a Machined and As-Forged Surface Finish

By Professor Ali Fatemi - The University of Toledo


Motivation and Objective of the Study


Fatigue fractures are the most common type of mechanical failures of components. As such failures typically initiate at the surface, surface condition plays a key role in fatigue life. Although many forgings are machined, some forgings are not machined in all critical areas subsequent to forging, such as the shank areas in forged connecting rods. To account for surface finish effect on fatigue behavior, surface correction factors are commonly used. These correction factors are typically based on data published in the 1940's. It has been found by several investigators that the existing data for as-forged surface condition is too conservative, which results in over-engineered designs, leading not only to increased cost, but also increased weight. In addition, this can reduce forging competitiveness in terms of cost and performance prediction in the early design stage, compared to alternative manufacturing processes. Therefore, FIERF and AISI sponsored this research to update data -especially forged surface finish factors - to reflect the advances in steel making and forging process technologies over the last 70 years.

The overall objective of this study was to conduct a systematic and comprehensive experimental investigation to evaluate and quantify forged surface finish effect at several hardness levels on fatigue behavior of commonly used forged steel. Two surface conditions were compared; a smooth-polished surface as the reference to a hot-forged surface. The heating methods were gas furnace heating as well as induction heating, to allow comparison of the two heating methods, as decarburization depth differs between the two methods. Since shot blasting is commonly used as a forged surface cleaning process with the additional benefit of inducing compressive residual stress, the hot-forged surface finish was evaluated with and without shot blasting. Some testing was also conducted to investigate the effect of the flash left by the forging process. For conclusions please click here; for the full report please visit our website www.forging.org under "Technology/Industry Research Reports".



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FIERF Seeking Additional Funding For Industry Research & Technology Development

To potentially grow the amount of government funding available for forging industry related technical research, the Foundation has retained The Genesis Group to act on the industry's behalf in Washington DC.


The language being requested asks the Defense Logistics Agency to "increase their support of research and development into advanced forging technologies" and "further, the agency is urged to increase its support of domestic forging manufacturing processes".


The Laurin Baker Group continues the outstanding job of representing the industry's public policy efforts (including ForgingPAC).  The focus of the Genesis Group will be solely on funding for technology development.


Letters of support have been sent by FIA Leadership and are being solicited from individual FIA Member Companies in the states of Senators on various relevant committees.


Watch Quick Read for updates as they become available, or contact Karen Lewis ([email protected] or 216.781.6260) for information at any time.


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Technical Conference Papers Available to Members

If you didn't attend the Forging Industry Technical Conference in April, you missed the best such conference in years.  Attendees cited the quality of the presentations, networking and the plant tours of HHI's Jernberg facilities as the value they received by their participation. 


As a FIA Member you can still benefit from the presentations of work being funded by FIERF and other research partners.  Technical papers from the conference are now available on-line as part of the Industry Technical Reports Library.   

Available papers include:


Effect of Forging Surface on Fatigue Behavior of Steels: A Literature Review (pdf)

 Ali Fatemi, University of Toledo, Research co-sponsored by Forging Industry Educational and Research Foundation (FIERF) and American Iron and Steel Institute (AISI).


Influence of Surface Finish on Bending Fatigue of Forged Steel Including Heating Method, Hardness, and Shot Cleaning Effects (pdf)

 Ali Fatemi, University of Toledo, Research co-sponsored by Forging Industry Educational and Research Foundation (FIERF) and American Iron and Steel Institute (AISI).


Heating & Cooling of Stock:


Electrodynamics, the Neglected Parameter in the Processing and Properties of Metals with Focus on Aluminum (pdf)

Jun Wang, North Carolina State University, FIERF Funded Project


Intricacies of Computer Simulation of Induction Heating Processes (pdf)Valery Rudnev, Inductotherm Group


Heat Treatment:


Effects of a Solution Anneal Quench Delay on Mechanical Properties of Aluminum 2219-T6 (pdf)

 Blair London, California Polytechnic State University




Flow Behavior of INCOLOY 945 During High Temperature Deformation (pdf)

Steve Coryell, Colorado School of Mines, 2009 FIERF Fellowship


MagForge: Cost Effective Ways to Forge Magnesium (pdf)

Fabrice Chevaleyre, Association Francaise de Forge


Property and Microstructure Variation in Forging Bar Steels (pdf)

Lee Rothleutner, Colorado School of Mines, Golden, CO, 2010 FIERF Fellowship


Quality Control:


Nondestructive Examination of Hydraulic Forging Press Components (pdf)

Ron Manganello, Carlesa NDE Services


Simulation & Modeling:


Thermal-Mechanical Modeling of Stainless Steel Forgings  (pdf)

Arthur A. Brown, Sandia National Laboratories

Techniques and Systems:

Eliminating Coal Dust in the Production of Ring Rolling Preforms (pdf)  

John Walters, Scientific Forming Technologies Corporation, FIERF Funded Project


Severe Plastic Deformation to Achieve Ultra-Fine Grains (pdf)

Prabir Chaudhury, Education and Consulting, LLC


Technologies for Rolling Profile Rings (pdf)

Martin Gellhaus, SMS Meer Wagner Banning Ring Rolling Division


Tooling & Lubrication:


Selection of Die Materials and Surface Treatments for Increasing Die Life in Hot and Warm Forging (pdf)

Taylan Altan, The Ohio State University


For more information on Industry Technology projects - or to discuss new projects - please contact FIA Technical Director Carola Sekreter ([email protected]) or 216.781.6260).


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2011 Defense Logistics Conference & Exhibition

"The Forging Industry was well represented at the 2011 Defense Logistics Agency Industry Conference & Exhibition. The IMT Partnership - PC Forge, Clifford Jacobs, and Ulven Forging interacted with DLA buyers, OEMs, and machine shops.  The FORGE-IT Team supported Defense Logistics Agency within the Forging and Casting R&D Booth while I H S marketed the National Forging Tooling Database to all links within the forging supply chains supporting the warfighter.  Senior DOD leaders provided insight into the future of defense spending and the challenges facing the military services and the industrial base. Contact Jon Tirpak at 843-760-4346 for more details on this annual event which connects suppliers to buyers." 


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