SBIR Phase I: Novel Radially Constricted Consolidation (RCC) Technique for Rapidly Engineered Forging Dies

这个小型企业创新研究第一阶段项目将开发一种工艺，显著降低(高达74%)锻模成本，提高模具寿命，同时降低锻件成本。该项目方法涉及使用称为RCC过程的近净形状制造过程。这一工艺一旦针对模具应用进行了优化，将取代现有方法中的几个高能量、昂贵的步骤。该工艺允许对表面化学进行局部控制，从而实现更好的金属流动和模腔填充，提高耐磨性和耐热性。该工艺结合了熔模铸造的成形能力和全密度粉末冶金的组织均匀性，以及锻件的强度。该工艺已成功地用于制造多种复杂形状的高温合金、钛合金和不锈钢原型零件。潜在的商业应用将是一种新的模具制造工艺。预计如果成功，每年可节省高达12亿美元的成本。

This Small Business Innovation Research Phase I project will develop a process to significantly lower (up to 74%) the cost of forging dies, improve die life, and at the same time lower the cost of forgings. The project method involves the use of a near-net-shape manufacturing process, called the RCC process. This process, once optimized for die applications, will be replacing several high energy, expensive steps in the existing methods. The process allows localized control of surface chemistry, which can lead to better metal flow and die cavity filling, improved resistance to wear and heat checking. The process combines the shape capability of investment casting with structural uniformity of full-density powder metallurgy, and strength of forgings. The process has been used successfully to manufacture several complex shaped superalloy, titanium alloy, and stainless steel prototype parts. The potential commercial application will be a new die making process. It is projected that an annual cost savings could be as much as $1.2 billion if successful.