Efficient process design for closure and healing of voids in open die forging of superhigh C-steel shaft

Abstract

In this study, simulation and experimental works are carried out to propose the efficient forging process design for manufacturing workroll made of 1.5wt%C high carbon steel. New forging process design is composed of incremental upsetting, diffusion boding and cogging process for efficient void closure and healing. Since the voids lie along the longitudinal direction of the ingot, the ingot is gradually deformed only in its radial direction during incremental upsetting until void closure takes place. After that, the closed voids are healed by diffusion bonding process in order to assign the strong bonding strength to the closed void and to prevent the re-opening of the closed voids during successive incremental upsetting and cogging process. Experimental works are also carried out to validate the proposed forging process design. In addition, the effect of temperature of diffusion bonding on bonding strength of the closed void is investigated. Finally, the analyses on microstructure at the diffusion-bonded interface and mechanical properties by tensile test are carried out as well. It was found out through simulation and experimental works that the quick void closure takes place by incremental upsetting and the closed void is strongly joined by diffusion bonding. It was confirmed that the process design proposed in this study can be applicable to manufacture the super high carbon workroll with microstructurally soundness.