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

这个小企业创新研究第一阶段项目将开发一种工艺，以显着降低（高达74%）锻造模具的成本，提高模具寿命，同时降低锻件的成本。项目方法包括使用一种接近净形状的制造过程，称为RCC过程。这个过程，一旦优化模具应用，将取代几个高能量，昂贵的步骤，在现有的方法。该工艺允许局部控制表面化学，这可以导致更好的金属流动和模具型腔填充，提高耐磨性和热检查。该工艺将熔模铸造的成形性能与全密度粉末冶金的组织均匀性和锻件的强度相结合。该工艺已成功地用于制造几种形状复杂的高温合金、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。如果成功，预计每年可节省多达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.