Ingot to billet conversion - simulating the cogging process

Project aim

To design an experiment, and simulate the thermomechanical processing of a nickel-based superalloy at an experimental scale to gain a better understanding that the process parameters have on the deformation and microstructural quality of the alloy.

Project background

Next-generation metallurgical manufacturing techniques require a new level of understanding of how metals and alloys deform under various new processes which subject metals to complex loading and forging conditions.

The project will address the critical knowledge gap for the thermo-mechanical process known as cogging by developing a miniature testing apparatus for studies at an experimental scale.

The constructed miniature cogging rig will be used to investigate microstructure-level deformation of selected high-performance structural alloys, specifically those used in turbine engines, to develop a better understanding of the material while undergoing the process at an industrial scale by translation through simulation.

Digital image correlation and crystal orientation mapping electron back-scatter diffraction (EBSD), will be used to measure the degree to which deformation is localised at the different microstructural features of the alloys.