Plenary Speakers

 

Dr. Ellen K. Cerreta

Group Leader for the Materials in Radiation and Dynamic Extremes Group (MST-8) at Los Alamos National Laboratory, Los Alamos, New Mexico, USA

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Ellen Cerreta is the Group Leader for the Materials in Radiation and Dynamic Extremes Group (MST-8) at Los Alamos National Laboratory.  She received her B.S in Aerospace Engineering from the University of Virginia and her M.S. and Ph.D. degrees in Materials Science and Engineering from Carnegie Mellon University.  After graduation, Ellen accepted a post doctoral position within the materials science division of Los Alamos.  She was converted to staff in 2003.  Since that time, Ellen’s work has included the study of the mechanical behavior of materials and microstructural characterization with a focus on the relationship between microstructure and dynamic materials properties.   At Los Alamos, Ellen leads a number of projects to investigate dynamic materials performance and utilizes this information to advance predictive capabilities for strength and damage in extreme environments. 

      Ellen has been a member of ASM since 2004 and her work with ASM has been multi-faceted.  She has served for almost 15 years as a reviewer for Materials Transactions A and since 2012 as a Key Reader for the journal.  She was a member of the ASM International Membership Committee from 2003-2009 where she worked to develop programs to attract early career professionals to the society.  Most recently, she has served on the AM&P Editorial Board and in 2012 was the chair.  Ellen is also an active member of TMS, where she is currently the Vice Chair of the Structural Materials Division.

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abstract

"Advanced Characterization for Quantifying and Modeling Deformation Due to Thermo-mechanical Processing in BCC metals"

The prediction of microstructure evolution during thermo-mechanical processing is a critical component of the capability to predict material performance. This is because microstructure

Evolution during deformation processing and the resulting heterogeneities are expected to strongly influence the material properties. However even for traditional deformation processing techniques like rolling and forming, prediction of microstructure is limited. Current crystal plasticity models fail to effectively capture this heterogeneous plastic deformation largely due to the gaps in our understanding of the local (anisotropic) properties at subā€micron length scales. With recent advances in nano-indentation testing and data analysis, there is now an unprecedented opportunity to reliably characterize mechanical behavior at these small length scales. Here, these protocols will be applied to pure tantalum samples deformed dynamically strain rates that are similar to those imposed under deformation processing conditions)  to predetermined strain levels. This local mechanical property data, together with the complimentary

structure information measured by electron backscatter diffraction (EBSD) will be used to investigate local changes in the mechanical behavior as a function of local crystal orientation. The aim is to gain insight into the evolution of microstructural features during macroscopic deformation and its subsequent influence on mechanical properties like strength.

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Prof. Masaaki Otsu

Department of Mechanical Engineering, Faculty of Engineering,
University of Fukui, Fukui, Japan

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Professor at University of Fukui, Japan (2011)
Associate Professor at Kumamoto University, Japan (2007)
Lecture at Kumamoto University, Japan (2002)
Research Associate at Osaka University, Japan (1998)
Conferred Degree of Doctor Engineering from Osaka University, Japan (1998)

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abstract

"Excellent Formability of Light Metals Sheets by Friction Stir Incremental Forming"

The authors have developed friction stir incremental forming method for forming magnesium alloy sheets without dies and external heating in 2009. The concept of friction stir incremental forming came from not local heating by friction but combining single point incremental sheet metal forming and friction stir welding for utilizing plastic flow by stirring. So the authors call friction stir incremental forming only in cases of occurring friction stirring phenomenon. Once friction stirring phenomenon occurs, light metal sheets such as magnesium and aluminum alloys show excellent formability up to several hundred percent elongation.

      In this keynote lecture, the results about friction stir incremental forming of light metals sheets from the beginning of development to the latest in our laboratory will be introduced. Comparison of formability by the conventional single point incremental sheet metal forming and friction stir incremental forming for magnesium alloys and aluminum alloys sheets will be talked. Difference of deformation mechanism between the conventional single point sheet metal forming and friction stir incremental forming as a result of numerical simulation will be also introduced.

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Prof. Jesus Talamantes-Silva

Group Design and Technology Director: Sheffield Forgemasters International Ltd. Sheffield, United Kingdom

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Born in Mexico, Jesus attended University in Monterrey at UANL-FIME (North-Eastern Mexico). After gaining MEng (Hons) in Mechanical and Electrical Engineering and a MSc degree in Engineering Materials he was awarded a PhD from the University of Sheffield for his studies on hot metal forming for British Steel (now TATA).

Whilst at the University of Sheffield, he was seconded to Corus Swinden Technology Centre (STC) before joining Sheffield Forgemasters International Ltd. in 2005 as Research and Development Manager. He was promoted to Group Research and Development Director in 2009. In 2012, he was promoted to Managing Director of the Sheffield Forgemasters Research and Development subsidiary: Sheffield Forgemasters RD26 Ltd.  In 2016, he was promoted to Group Design and Technology Director and in addition to RD26 Ltd.; he is now also responsible for Sheffield Forgemasters’ oil and gas subsidiary: Vulcan SFM Ltd. 

Jesus has managed and coordinated large industrial development projects from his time at Sheffield University and British Steel and since joining Sheffield Forgemasters he has secured and managed UK government sponsored industrial projects in excess of £17M.

His current work includes a wide range of projects both within the Forgemasters Group and at the request of external customers. Here, metallurgical and engineering solutions are determined for a wide variety of processes and include applications for defence, oil and gas, power generation, civil nuclear, marine and heavy engineering.

He is visiting Professor of Materials Science and Engineering at the University of Sheffield and sits on the Research Board at the Nuclear Advanced Manufacturing Research Centre (NAMRC). He is also Member of the “Bulk Metal forming Committee” of the Materials Science and Technology Division in The Institute of Materials, Minerals and Mining (IOM3), London, UK and he is member of the Sheffield City Region Science and Innovation Board.

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abstract

"The role of simulation in the production of ultra large components"

This presentation highlights the importance of process modelling in the Manufacture of bespoke, high integrity, critical components such as large forgings and castings.

The production of ultra large components with the appropriate combination of strength, toughness and degradation resistance can be a difficult task. Close control of key manufacturing parameters such as chemical composition, heat treatment temperatures and discard practice is, therefore, essential. Material capability can be determined through process modelling; this practice can identify limitations from both an operational and material standpoint. When manufacturing and material capabilities are maximised, adopting new materials may be key to enhancing product performance and life. Again, computer simulations can give insight into new material behaviour and key characteristics. Of particular interest is the control of essential manufacturing parameters that determine product homogeneity in regions distant from test locations. In a production item, homogeneity and mechanical properties in these locations cannot be measured by testing or examination. Of immediate consideration is the issue of realistic and repeatable manufacturing controls to provide a sustainable process. This process needs to lie within the limits of the computer simulated outcomes in order to contain process heterogeneity within prescribed tolerances. Determination of the limits of material and process capability, required for operating tolerances, can only be realised by a holistic approach to computer simulation techniques well beyond the time, human and financial constraints traditionally applied.

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Prof. Elena Pereloma

Senior Professor of Physical Metallurgy and the Director of UoW Electron Microscopy Centre, University of Wollongong, Australia

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Elena Pereloma earned her PhD at the  Institute for Metal Physics, National Academy of Sciences, Ukraine in 1987. Currently, she is the Senior Professor of Physical Metallurgy and the Director of UoW Electron Microscopy Centre, University of Wollongong, Australia.  Professor Pereloma was the Director of BlueScope Steel Metallurgy Centre (2007-2013) and of Engineering Materials Institute Research Strength (2008-2012), University of Wollongong after spending 11 years at Monash University, Australia in various academic positions.

Professor Pereloma’s areas of expertise include processing-microstructure-mechanical properties relationships, phase transformations, alloy design and advanced characterisation techniques (electron microscopy and atom probe tomography) of steels and alloys. She has authored more than 200 papers in leading international journals, edited a book and two conference proceedings.

Professor Pereloma received numerous awards for her research including Honorary Doctor of Sciences and V.G. Kurdjumov Medal, Institute for Metal Physics, Ukraine, Sawamura Award, The Iron and Steel Institute of Japan, the Florence M. Taylor Medal, The Institute of Materials Engineering Australasia.

Professor Pereloma has served as a Research Evaluation Committee member on the Engineering and Environmental Sciences panel for Excellence in Research for Australia (ERA) 2010 and 2015.

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abstract

"Effect of Processing Parameters on Microstructure and Mechanical Properties of Multiphase Steels Produced by Laboratory Simulated Strip Casting"

Direct strip casting technology is a novel process which significantly reduces the environmental impact of steelmaking. To-date, this approach was utilised primarily for austenitic stainless steels, plain carbon and high strength low alloyed steels. In this presentation, the results of feasibility study on production of conventional dual-phase (DP) and transformation-induced plasticity (TRIP) steels using laboratory simulation of the strip casting are reported. In particular, the effects of deformation and coiling temperatures on the microstructure and tensile properties are considered. Combination of both conventional and advanced characterisation techniques allowed in-depth microstructure characterisation and insight into its development.

The results have shown that despite the main limitation in controlling the microstructure of steels during strip casting imposed by the availability of only one rolling stand, it is possible to achieve the mechanical properties of DP steels comparable to those of hot rolled ones.

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Dr Lee Shaw

Director of Technology and NPD&I, Europe Forgings and Metals Alcoa Forgings and Extrusions, Sheffield, UK

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Lee Shaw holds bachelor’s and doctor’s degrees in metallurgy both of which are from the University of Sheffield, England.

After completing his degrees he worked for a number of years for the UK government before joining a business manufacturing high integrity steels and nickel base alloys and components predominantly for the aerospace industries but also other demanding engineering applications. This business eventually became part of ATI Allvac and this added titanium alloys to his portfolio of experience.

After working for what eventually became ATI Allvac for almost 15 years and ultimately in the role of technical lead for their UK site he moved to Firth Rixson as Technical Director at their disc forging business in Darley Dale in 2004. In 2007 he changed role within Firth Rixson to Technical Development Director with responsibilities across all the Firth Rixson businesses. Lee has worked for Firth Rixson since this time apart from a 2 year period from 2009 working for a Cambridge University spin-off business as Director of Technology.

Since Firth Rixson was acquired by Alcoa in 2014 he has been Director of Technology and New Product Development for the European Forging and Metals businesses.

Lee has extensive experience in specialist melting, production of billet and forged components in special iron, nickel and titanium based alloys. These products being made by a wide variety of process for diverse applications in Aerospace, oil and gas, transportation, mining, off highway and other high integrity engineering applications.

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abstract

"Forgings for Critical Applications; Past, Present and Future"

Dr Lee Shaw,
Director of Technology and New Products
Alcoa Metals and Forgings, Europe

Alcoa is a producer of specialist alloys, forgings and machined components for industries requiring forged components for critical applications. The business is thought of as being in the aluminium production business, which it is. However, there is much more to the business particularly through the recent acquisitions of Firth Rixson and RTI. This has added considerable extra capability to the business which already had broad forging capability in titanium alloys, steel and nickel alloys in addition to that of aluminium.

The presentation will describe the forging of metals to produce components for critical applications and how the processes have developed over time to their current state of understanding. The topics of microstructural development, property development and defect avoidance will be discussed. Additionally, the importance of modelling will be presented in the production of high integrity components, typically used for the aerospace, power generation, medical, automotive and petrochemical industries.

The presenter will attempt to look into the future of forging for critical components and mention some possible processes to address cost, time to production, properties and performance of such items.

Specific examples of products made by Alcoa will be discussed. Some examples of such product are shown in the following: Figure 1: Closed die forged superalloy disc forgings for gas turbine engines. Figure.2: Forward/backward extruded components for aerospace and automotive applications.

Figure 1: Typical small superalloy and titanium alloy discs

 

Figure 2: Forward/Backward extruded aeroengine shafts.

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