Methods, systems, and apparatus for assessing tool dies

Abstract

Various examples are provided related to a micro-scale forging apparatus. In one example, a micro-scale forging apparatus includes a hammering device and a die configured to removably couple to the hammering device. The die can include a punch and a plate, and the hammering device can be configured to strike the plate with the punch. An example of a method for assessing a die for die repair includes simulating forging by striking a plate with a punch a number of times and evaluating a surface of the plate, the punch, or both. Another example of a method for assessing a die for die repair includes forging a number of parts with the die and evaluating a surface of the die.

Description

DOCKET NO 921402-2030METHODS, SYSTEMS, AND APPARATUS FOR ASSESSING TOOL DIESCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of, U.S. provisional application entitled “Methods, Systems, and Apparatus for Assessing Tool Dies” having serial no.63 / 745,966, filed January 16, 2025, which is hereby incorporated by reference in its entirety.BACKGROUND

[0002] The forging industry can suffer from loss of forging dies due to wear and damage. These damaged dies often must be replaced or repaired. Replacing dies can become costly and wasteful. Repairing dies takes time, additionally these repairs can be ineffective, resulting in flaking and cracking that reduces the repaired die’s life span.SUMMARY

[0003] In accordance with the purpose(s) of the present disclosure, as embodied and broadly described herein, the disclosure, in one aspect, relates to methods, systems, and apparatus for evaluating tool dies, tool die coatings, and tool die lubricants.

[0004] Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims. In addition, all optional and preferred features and modifications of the described embodiments are usable in all aspects of the disclosure taught herein. Furthermore, the individual features of the dependent claims, as well as all optional and preferred features and modifications of the described embodiments are combinable and interchangeable with one another.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.DOCKET NO 921402-2030

[0006] FIG. 1 is a diagram of Vickers hardness testing from the laser-coated surface, across the interface and heat affected zone, and into the steel substrate, in accordance with various embodiments of the present disclosure. Measurements were collected in a grid with eleven rows and five columns. Hardness indents made 20 μm apart.

[0007] FIGS. 2A-2C show CALPHAD simulation results for Fe(25) at (FIG. 2A) 600 °C, (FIG. 2B) 800 °C, and (FIG. 2C) 1000 °C, in accordance with various embodiments of the present disclosure.

[0008] FIGS. 3A-3C show CALPHAD simulation results for Fe(30) at (FIG. 3A) 600 °C, (FIG. 3B) 800 °C, and (FIG. 3C) 1000 °C, in accordance with various embodiments of the present disclosure.

[0009] FIGS. 4A-4C show CALPHAD simulation results for Fe(35) at (FIG. 4A) 600 °C, (FIG. 4B) 800 °C, and (FIG. 4C) 1000 °C, in accordance with various embodiments of the present disclosure.

[0010] FIGS. 5A-5C show CALPHAD simulation results for Fe(40) at (FIG. 5A) 600 °C, (FIG. 5B) 800 °C, and (FIG. 5C) 1000 °C, in accordance with various embodiments of the present disclosure.

[0011] FIG. 6 shows SEM images of preliminary CCA coatings with constant Fe(40) composition and varying laser power from 700 W, 800 W, and 900 W. EDS maps of iron in coatings show CCA-H13 interface, in accordance with various embodiments of the present disclosure.

[0012] FIGS. 7A-7C show SEM images of preliminary CCA coatings with constant 900 W laser power and varying composition between (FIG. 7A) Fe(25), (FIG. 7B) Fe(30), and (FIG.7C) Fe(35), respectively, in accordance with various embodiments of the present disclosure.

[0013] FIG. 8 shows Vickers hardness test results for Fe(25), Fe(30), and Fe(35) relative to hardness of bulk H13, in accordance with various embodiments of the present disclosure.

[0014] FIGS. 9A and 9B show particle size distribution measurements of (FIG. 9A) Fe30 and (FIG. 9B) Fe35, which were applied to the forging dies, in accordance with various embodiments of the present disclosure.

[0015] FIGS. 10A-10F show SEM images of constituent powders of (FIG. 10A) Fe, (FIG.10B) Co, (FIG. 10C) Cr, (FIG. 10D) Ni, (FIG. 10E) Al, and (FIG. 10F) Ti for CCA before mixing, in accordance with various embodiments of the present disclosure.DOCKET NO 921402-2030

[0016] FIGS. 11A-11D show SEM images at two different magnifications of the mixed CCA powders for (FIG. 11A)-(FIG. 11 B) Fe(30) and (FIG. 11C)-(FIG. 11 D) Fe(35), respectively, in accordance with various embodiments of the present disclosure.

[0017] FIGS. 12A-12H show EDS images of (FIG. 12A)-(FIG. 12D) Fe(30) and (FIG. 12E)-(FIG. 12H) Fe(35) CCA coatings with scans of Fe, Co, Ni, and all element layered image before polishing, in accordance with various embodiments of the present disclosure.

[0018] FIGS. 13A-13C show (FIG. 13A) SEM image and corresponding EDS images of (FIG. 13B) Fe and (FIG. 13C) Cr distributions of an Fe(35) coating cross-section after polishing, which highlights coating thickness loss due to polishing to a flat surface, in accordance with various embodiments of the present disclosure.

[0019] FIGS. 14A and 14B show 2D DeBye-Scherrer XRD patterns and corresponding integrated and normalized 1-D XRD lineouts with identified (hkl) diffraction peaks for the (FIG.14A) Fe(30) and (FIG. 14B) Fe(35) coatings, in accordance with various embodiments of the present disclosure.

[0020] FIGS. 15A and 15B show Vickers hardness maps of coating cross-sections for (FIG. 15A) Fe(35) and (FIG. 15B) Fe(30) coatings showing 3 hardness regions vs bulk H13 steel, in accordance with various embodiments of the present disclosure.

[0021] FIG. 16 shows photographs of the parts forged with the dies in three different orientations before cutting flash (right image in each box) and after cutting flash, i.e. finished part (left image in each box), in accordance with various embodiments of the present disclosure.

[0022] FIGS. 17A-17E show (FIG. 17A) a photograph of the Fe(30) die head after 21,000 cycles with (FIG. 17B) magnified image (red box) and further magnification of (FIG. 17C) compressive stress region (blue box), (FIG. 17D) shear stress region (green box), and (FIG.17E) compressive stress region (purple box), in accordance with various embodiments of the present disclosure.

[0023] FIG. 18 shows an example die design using a hydraulic press in accordance with various embodiments of the present disclosure.

[0024] FIGS. 19A-19H show various die designs in accordance with various embodiments of the present disclosure. FIGS. 19A-C show an example die design without alteration and with a coating applied to the bottom die. FIGS. 19D and 19E show an example die design withDOCKET NO 921402-2030punch alteration and with a coating applied to the bottom die. In the examples of FIGS. 19D and 19E, the punch base can be kept solid to replicate a die. FIGS. 19F-19H show an example die design with punch and die alteration and with a coating applied to the top die. In the examples of FIGS. 19F-19H, the base can be solid and flat and the tip of the top die can be set to reduced die detentions.

[0025] FIG. 20 shows a table of example dimensions for die diameters of 6 mm, 12 mm, and 18 mm in accordance with various embodiments of the present disclosure.

[0026] Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or can be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.DETAILED DESCRIPTION

[0027] Many modifications and other embodiments disclosed herein will come to mind to one skilled in the art to which the disclosed compositions and methods pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosures are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. The skilled artisan will recognize many variants and adaptations of the aspects described herein. These variants and adaptations are intended to be included in the teachings of this disclosure and to be encompassed by the claims herein.

[0028] Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

[0029] As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of the present disclosure.

[0030] Any recited method can be carried out in the order of events recited or in any other order that is logically possible. That is, unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps beDOCKET NO 921402-2030performed in a specific order. Accordingly, where a method claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification.

[0031] All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and / or materials in connection with which the publications are cited. The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided herein can be different from the actual publication dates, which can require independent confirmation.

[0032] While aspects of the present disclosure can be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of skill in the art will understand that each aspect of the present disclosure can be described and claimed in any statutory class.

[0033] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosed compositions and methods belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0034] Prior to describing the various aspects of the present disclosure, the following definitions are provided and should be used unless otherwise indicated. Additional terms may be defined elsewhere in the present disclosure.A. Definitions

[0035] As used herein, “comprising" is to be interpreted as specifying the presence of the stated features, integers, steps, or components as referred to, but does not preclude the presence or addition of one or more features, integers, steps, or components, or groupsDOCKET NO 921402-2030thereof. Moreover, each of the terms “by”, “comprising,” “comprises”, “comprised of,” “including,” “includes,” “included,” “involving,” “involves,” “involved,” and “such as” are used in their open, non-limiting sense and may be used interchangeably. Further, the term “comprising” is intended to include examples and aspects encompassed by the terms “consisting essentially of’ and “consisting of.” Similarly, the term “consisting essentially of’ is intended to include examples encompassed by the term “consisting of.

[0036] As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a die”, “a coating”, or “a surface” includes, but is not limited to, two or more such dies, coatings, surfaces, and the like.

[0037] It should be noted that ratios, concentrations, amounts, and other numerical data can be expressed herein in a range format. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms a further aspect. For example, if the value “about 10” is disclosed, then “10” is also disclosed.

[0038] When a range is expressed, a further aspect includes from the one particular value and / or to the other particular value. For example, where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure, e.g. the phrase “xto y” includes the range from ‘x’ to ‘y’ as well as the range greater than ‘x’ and less than ‘y’. The range can also be expressed as an upper limit, e.g. ‘about x, y, z, or less’ and should be interpreted to include the specific ranges of ‘about x’, ‘about y’, and ‘about z’ as well as the ranges of ‘less than x’, less than y’, and ‘less than z’. Likewise, the phrase ‘about x, y, z, or greater’ should be interpreted to include the specific ranges of ‘about x’, ‘about y’, and ‘about z’ as well as the ranges of ‘greater than x’, greater than y’, and ‘greater than z’. In addition, the phrase “about ‘x’ to ‘y’”, where ‘x’ and ‘y’ are numerical values, includes “about x’ to about ‘y’”.DOCKET NO 921402-2030

[0039] It is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. To illustrate, a numerical range of “about 0.1% to 5%” should be interpreted to include not only the explicitly recited values of about 0.1% to about 5%, but also include individual values (e.g., about 1%, about 2%, about 3%, and about 4%) and the sub-ranges (e.g., about 0.5% to about 1.1%; about 5% to about 2.4%; about 0.5% to about 3.2%, and about 0.5% to about 4.4%, and other possible sub-ranges) within the indicated range.

[0040] As used herein, the terms “about,” “approximate,” “at or about,” and “substantially” mean that the amount or value in question can be the exact value or a value that provides equivalent results or effects as recited in the claims or taught herein. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact but may be approximate and / or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art such that equivalent results or effects are obtained. In some circumstances, the value that provides equivalent results or effects cannot be reasonably determined. In such cases, it is generally understood, as used herein, that “about” and “at or about” mean the nominal value indicated ±10% variation unless otherwise indicated or inferred. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about,” “approximate,” or “at or about” whether or not expressly stated to be such. It is understood that where “about,” “approximate,” or “at or about” is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.

[0041] As used herein, the terms “optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0042] Unless otherwise specified, pressures referred to herein are based on atmospheric pressure (i.e. one atmosphere).B. Discussion

[0043] Disclosed herein are methods, systems, and apparatuses that can enable relatively quick assessment of die-heads, die-head coatings, die-head lubricants, and other similar die-DOCKET NO 921402-2030head improvements for forging machines (e.g., machines configured for drop forging, press forging, upset forging, roll forging, precision forging, isothermal forging, and the like). Enabling faster assessment of die-heads and their coatings could enable faster adoption of new coating techniques such as laser engineered net shaping (LENS), direct energy deposition (DED), and other additive manufacturing (AM) processes due to the ability to test the materials more quickly on a small scale and at lower cost of materials and time. This could lead to extended die-head lifetime by allowing more rapid development of improved coatings. The faster assessment could also reduce time and costs associated with replacing or repairing worn or damaged die-heads. The methods, systems, and apparatus disclosed herein can be used to translate the performance of industrial-scale die-heads, die-head coatings, die-head lubricants, and the like on a smaller scale.

[0044] In one aspect, disclosed is a micro-scale apparatus (e.g., micro-scale forging machine) configured to assess die-heads and their associated coatings and lubricants. In a further aspect, the micro-scale apparatus can comprise small flat cylindrical punches which can be composed of a standard die material (e.g., H13 steel and FXT2 steel). The replaceable small flat cylindrical punches can be on the scale of about 200 pm to about 10 mm in diameter. The punch can be attached to a small hammering component configured for repeated striking of a base plate. The base plate can comprise a metal or metal alloy (e.g., aluminum alloy). The apparatus can be configured to the punch, the base plate, or a combination thereof.

[0045] Also disclosed is a micro-scale forging apparatus comprising a hammering device and a die configured to removably couple to the hammering device, wherein the die comprises a punch and a plate, wherein the hammering device is configured to strike the plate with the punch. The die can comprise one or more metals, such as H13 steel or FXT2 steel. The punch can have a variety of dimensions and geometries and can be composed of a standard die material. In an aspect, the punch has a diameter of approximately 200 pm to approximately 10 mm. In various aspects, the punch, the plate, or both can be coated. In various aspects, the punch, the plate, or both can be coated with one or more complex concentrated alloys (CCA), one or more high entropy alloys (HEA), or a nitride coating. In an aspect, the hammering device comprises a hydraulic press, one or more mechanical powered hammers and an electric motor, or one or more eccentric crank gears and a motor.

[0046] In one aspect, a system can comprise a micro-scale apparatus configured to assess die-heads and a computing device, which can include a processor, a memory, and / or a network interface. In one aspect, the computing device can be coupled to a network. TheDOCKET NO 921402-2030computing device can be embodied in the form of a personal computer (e.g., a desktop computer, a laptop computer, or similar device), a mobile computing device (e.g., personal digital assistants, cellular telephones, smartphones, web pads, tablet computer systems, music players, portable game consoles, electronic book readers, and similar devices), media playback devices (e.g., media streaming devices, Blu-ray® players, digital video disc (DVD) players, set-top boxes, and similar devices), a videogame console, or other devices with like capability. The computing device can include one or more displays, such as liquid crystal displays (LCDs), gas plasma-based flat panel displays, organic light emitting diode (OLED) displays, electrophoretic ink (“E-ink”) displays, projectors, or other types of display devices. In some instances, the display can be a component of the computing device or can be connected to the computing device through a wired or wireless connection. In some aspects, the display can include a user interface.

[0047] In another aspect, the computing device can have a data store. The data store can be representative of a plurality of data stores, which can include relational databases or nonrelational databases such as object-oriented databases, hierarchical databases, hash tables or similar key-value data stores, as well as other data storage applications or data structures. Moreover, combinations of these databases, data storage applications, and / or data structures may be used together to provide a single, logical, data store. Various data can be stored in the data store that is accessible to the computing device. The data stored in the data store is associated with the operation of the various applications or functional entities described below. This data can include analyte measurement, a calculated analyte concentration based on the analyte measurement, and / or timestamps of when analyte measurement is taken.

[0048] The computing device can be configured to collect, obtain, and / or receive data through the network, and store the data in the data store. The computing device can be configured to render a user interface on the display. The computing device can be configured to execute various applications such as an application for controlling various aspects of the systems disclosed herein or executing various aspects of the methods disclosed herein.

[0049] Also disclosed is a method for assessing die-heads, die-head coatings, die-head lubricants, and the like using the micro-scale apparatus. The punches of the micro-scale apparatus can be assessed with and without coatings from AM processes such as LENS and DED, and / or from conventional methods such as welding or plating. In one aspect, the method can comprise using H13 steel punches without any coating and H13 steel punches with a coating. In a further aspect, the coating can be a laser-coating of a complex concentrated alloyDOCKET NO 921402-2030(CCA) from LENS. The rate and load of the strike of the small hammering component can be tunable and controlled to simulate similar conditions to industrial scale forging. After each strike or after a set number of strikes (e.g., 5 or 20), the plate can be moved a small distance far away enough to not experience any influence from the previous strike. For example, the plate can be moved a distance far away enough that the strike at the new location does not overlap with the strike(s) to the previous location This process can be automated and repeated for up to about 100 cycles, about 1,000 cycles, about 10,000 cycles, or more cycles, depending on the diameter of the small cylindrical punch and on fracture and / or fatigue performance. The punches can be assessed before, during ( / .e., interrupted testing), and after testing using various assessment methods such as optical microscopy, scanning electron microscopy, and energy dispersive spectroscopy. The results can be compared to determine the validity of the micro-scale forging machine and to account for any size effects observed between a micro-scale and an industrial scale. These characterization tools can allow for inspection of surface changes such as material loss and cracking as a function of number of strikes.

[0050] Also disclosed is a method of assessing a die for die repair, comprising simulating forging by striking a plate with a punch a number of times and evaluating a surface of the punch, the plate, or both. In an aspect, evaluating the surface of the punch, the plate, or both further comprises assessing the surface using one or more of optical microscopy, scanning electron microscopy, dilatometry, or energy dispersive spectroscopy. In an aspect, evaluating the surface of the punch, the plate, or both can be performed prior to simulating forging. In an aspect, the surface of the punch, the plate, or both can be coated prior to simulating forging. In an aspect, the number of times can be based at least in part on an evaluation of the surface of the punch, the plate, or both. In an aspect, the punch, the plate, or both can be heated prior to simulating forging. In an aspect, a lubricant can be applied to the surface of the punch, the plate, or both prior to simulating forging.

[0051] Also disclosed is a method of assessing a die for die repair, comprising forging a number of parts with the die and evaluating a surface of the die. Evaluating the surface of the die can further comprise assessing the surface using one or more of optical microscopy, scanning electron microscopy, dilatometry, or energy dispersive spectroscopy. In an aspect, the surface of the die can be evaluated prior to forging the number of parts. In an aspect, the surface of the die can be coated prior to forging the number of parts. In an aspect, the number of parts can be based at least in part on an evaluation of the surface of the die. In an aspect,DOCKET NO 921402-2030the die can be heated prior to forging the number of parts. In an aspect, a lubricant can be applied to the surface of the die prior to forging the number of parts. In another aspect, the surface of the die can be coated using one or more additive manufacturing processes, welding, plating, or a combination of any thereof.

[0052] It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.C. Aspects

[0053] The following listing of exemplary aspects supports and is supported by the disclosure provided herein.

[0054] Aspect 1. A micro-scale forging apparatus, comprising a hammering device and a die configured to removably couple to the hammering device, wherein the die comprises a punch and a plate, wherein the hammering device is configured to strike the plate with the punch.

[0055] Aspect 2. The micro-scale forging apparatus of aspect 1, wherein the punch, the plate, or both are coated.

[0056] Aspect 3. The micro-scale forging apparatus of aspect 1 or 2, wherein the die comprises one or more metals.

[0057] Aspect 4. The micro-scale forging apparatus of any one of aspects 1-3, wherein the die comprises H13 steel or FXT2 steel.

[0058] Aspect 5. The micro-scale forging apparatus of any one of aspects 1-4, wherein the punch has a diameter of approximately 200 pm to approximately 10 mm.

[0059] Aspect 6. The micro-scale forging apparatus of any one of aspects 1-5, wherein the punch, the plate, or both are coated with one or more complex concentrated alloys (CCA), one or more high entropy alloys (HEA), or a nitride coating.

[0060] Aspect 7. The micro-scale forging apparatus of any one of aspects 1-6, wherein the hammering device comprises a hydraulic press, one or more mechanical powered hammers and an electric motor, or one or more eccentric crank gears and a motor.DOCKET NO 921402-2030

[0061] Aspect 8. A method of assessing a die for die repair, comprising simulating forging by striking a plate with a punch a number of times and evaluating a surface of the punch, the plate, or both.

[0062] Aspect 9. The method of aspect 8, wherein evaluating the surface of the punch, the plate, or both further comprises assessing the surface using one or more of optical microscopy, scanning electron microscopy, dilatometry, or energy dispersive spectroscopy.

[0063] Aspect 10. The method of aspect 8 or 9, further comprising evaluating the surface of the punch, the plate, or both prior to simulating forging.

[0064] Aspect 11. The method of any one of aspects 8-10, further comprising coating the surface of the punch, the plate, or both prior to simulating forging.

[0065] Aspect 12. The method of any one of aspects 8-11, wherein the number of times is based at least in part on an evaluation of the surface of the punch, the plate, or both.

[0066] Aspect 13. The method of anyone of aspects 8-12, further comprising heating the punch, the plate, or both prior to simulating forging.

[0067] Aspect 14. The method of any one of aspects 8-13, further comprising applying a lubricant to the surface of the punch, the plate, or both prior to simulating forging.

[0068] Aspect 15. A method of assessing a die for die repair, comprising forging a number of parts with the die and evaluating a surface of the die.

[0069] Aspect 16. The method of aspect 15, wherein evaluating the surface of the die further comprises assessing the surface using one or more of optical microscopy, scanning electron microscopy, dilatometry, or energy dispersive spectroscopy.

[0070] Aspect 17. The method of aspect 15 or 16, further comprising evaluating the surface of the die prior to forging the number of parts.

[0071] Aspect 18. The method of any one of aspects 15-17, further comprising coating the surface of the die prior to forging the number of parts.

[0072] Aspect 19. The method of any one of aspects 15-18, wherein the number of parts is based at least in part on an evaluation of the surface of the die.

[0073] Aspect 20. The method of any one of aspects 15-19, further comprising heating the die prior to forging the number of parts.DOCKET NO 921402-2030

[0074] Aspect 21. The method of any one of aspects 15-20, further comprising applying a lubricant to the surface of the die prior to forging the number of parts.

[0075] Aspect 22. The method of any one of aspects 15-21, further comprising coating the surface of the die using one or more additive manufacturing processes, welding, plating, or a combination of any thereof.

[0076] From the foregoing, it will be seen that aspects herein are well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure.

[0077] While specific elements and steps are discussed in connection to one another, it is understood that any element and / or steps provided herein is contemplated as being combinable with any other elements and / or steps regardless of explicit provision of the same while still being within the scope provided herein.

[0078] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

[0079] Since many possible aspects may be made without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings and detailed description is to be interpreted as illustrative and not in a limiting sense.

[0080] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to be limiting. The skilled artisan will recognize many variants and adaptations of the aspects described herein. These variants and adaptations are intended to be included in the teachings of this disclosure and to be encompassed by the claims herein.

[0081] Now having described the aspects of the present disclosure, in general, the following Examples describe some additional aspects of the present disclosure. While aspects of the present disclosure are described in connection with the following examples and the corresponding text and figures, there is no intent to limit aspects of the present disclosure to this description. On the contrary, the intent is to cover all alternatives, modifications, and equivalents included within the spirit and scope of the present disclosure.D. Examples1. Example 1DOCKET NO 921402-2030

[0082] Complex concentrated alloys (CCAs) are a novel class of alloys, which encompasses multi-element, multi-phase alloys with one or no primary element. These CCAs can be tailored to obtain various properties based on application. The effectiveness of using laser cladding to coat H13 steel die heads with FeCoNiCrTiAl CCAs to extend wear lifetime was explored. Industrial forging dies can experience extreme conditions, often resulting in fracture at the end of their fatigue life. To improve the lifetime of the dies, composition and laser fluence were varied to identify the optimal CCA coating parameters for these dies. Coating quality was investigated by observing porosity, coating adhesion, and gradient microstructural changes using scanning electron microscopy (SEM), and by observing Vickers hardness across the cross-sectional interface from the CCA to the bulk H13 steel. Based on these observations, two CCAs (Fe0.35Co0.25Ni0.2Cr0.1Ti0.06AI0.04 and Fe0.3Co0.3Ni0.2Cr0.1Ti0.06AI0.04) were selected for coating using the optimal parameters and applied to two forging dies for industrial testing. The results show that using CCAs to extend die head lifespan can provide a more cost-effective alternative to replacement of H13 steel dies.Motivation

[0083] The forging industry suffers from loss of forging dies due to wear and damage. These damaged dies must be replaced or repaired. Replacing dies becomes costly and wasteful. Repairing dies takes time, additionally these repairs can be ineffective, resulting in flaking and cracking that reduces the repaired die’s life span. An alloy coating on the head of the die can at once repair and strengthen the die.

[0084] Multicomponent alloys can be an attractive option for applications requiring high wear resistance and high temperature toughness. High Entropy Alloys (HEAs) are fairly well-known, being a multicomponent alloy of 5 or more near equi-atomic metals that create a structure with high configurational entropy. These HEAs can exhibit excellent wear resistance and high temperature toughness depending on the alloying components.

[0085] Complex concentrated alloys (CCAs) are a broad category of alloys which includes HEAs. CCAs can be an attractive option for coating and repairing these worn dies. This broad range of compositions can allow for a tunable range of properties such as wear resistance and high temperature performance which can be desirable for this application.

[0086] Various embodiments of the present disclosure aim to improve the repair process for worn forging dies, improving surface hardness and die-head life. Laser cladding wasDOCKET NO 921402-2030studied as a processing route for repairing the worn dies by applying a coating of complex concentrated alloy to develop a time-efficient process and effective coating.Objectives

[0087] The objective is to improve forging die-head wear resistance via laser-coating an optimized CCA onto the worn and resurfaced die-head. This was developed by using laser cladding to apply an iron-based CCA coating on used dies and evaluating their performance in industrial use and material testing. CALPHAD simulation was used to determine the ideal range of CCA compositions. Mechanical testing and microstructure analysis were performed to determine the ideal laser parameters and CCA compositions. The ideal laser parameters and two ideal CCA compositions were then applied to two different forging dies and two sacrificial tiles. The forging dies were sent for industrial testing while the sacrificial tiles were evaluated with mechanical testing, XRD, and SEM to identify the dilution, hardness, and phase composition. The aim of this testing is to use the CCA coating and laser processing to improve the die life compared to the standard die life of 19,000 parts.Contribution

[0088] Replacing worn dies can be expensive and wasteful. Various embodiments of the present disclosure explore alternative options for repairing damaged dies instead of replacing them. The alloy developed from the FeCoNiCrTiAl CCA system can be extended to other applications requiring wear resistance and high temperature performance similar to conditions that the forging die is exposed to, lowering costs associated with repairs and replacement in those applications.BackgroundLaser Coating Process

[0089] Laser-based processing methods are becoming increasingly popular for surface treatments due to their high energy density, coherence, and control. There are various processes that use lasers for surface treatments such as laser peening, laser remelting, and laser cladding. Laser cladding uses a laser to rapidly melt cladding powders onto a substrate. This process can create a large temperature gradient, resulting in a fine microstructure with a tough coating. Laser-based processing methods have shown promise for processing various forms of steel, including complex high alloy steels. The melting and subsequent rapid solidification can form an ultrafine grain structure. Laser cladding is an emerging technique for repairing cracked and worn parts, strengthening them so that they can last longer. The mainDOCKET NO 921402-2030parameters that can alter the quality of the coating from laser cladding include laser power, laser scan speed, preheating temperature, carrier gas flow, shielding gas flow, and powder mass flow rate. The high degree of control allows for minimal dilution of the coating with the substrate material and strong adhesion between the coating and substrate, promoting a high erosion resistance.

[0090] Iron-based high entropy alloys (HEAs) and complex concentrated alloys (CCAs) have gained in importance for laser cladding due to their compatibility with common iron-based die materials. These alloys can exhibit a unique combination of properties not observed in conventional alloys.

[0091] The interaction between laser and material is broken into three different modes. The first mode is conduction, which involves transfer of heat from the laser to the surface of the material that is being processed and from the surface to the volume of the material immediately around it. The second mode is the transition mode, which is just the transition between the conduction mode and the keyholing mode. The final mode is the keyholing mode. During this mode, the heat of the metal surface can be sufficient to locally boil the material, causing the material to form depressions and cavities. These cavities may continue to grow into the depth of the material with continued laser irradiation. Inside of these cavities, the lasers are continuously reflected, resulting in higher absorptivity in the cavities than on the original surface. These cavities can form into keyholes or pores, both of which can be detrimental to material performance. It is for this reason that maintaining a balance of laser power can be vital. Excessively low laser fluence can fail to melt the powders and substrate sufficiently, leading to low adhesion while excessively high laser fluence can encourage the formation of keyholes and keyhole pores.

[0092] Laser cladding uses a laser to heat a powder mixture at a high heating and subsequent cooling rate. This brings the powder mixture above the melting point, allowing for a homogeneous coating. The high cooling rate after melting discourages the formation of intermetallic phases. A significant factor in the effectiveness of this process and the adhesion between coating and substrate is the laser fluence. The laser fluence can determine the heat affected zone which is the area in which the substrate interacts with the coating. Low laser fluence can result in poor adhesion with a porous interface with the substrate. Laser fluence that is too high can result in excessive melting of the substrate material, diluting the coating. Laser fluence can be calculated using Equation 1:DOCKET NO 921402-2030F = (P₀(d / v)) / A (Equation 1) where F is the laser fluence, P0is the laser power, d is the beam diameter, v is the scanning speed, and A is the beam’s cross-sectional area, respectively.

[0093] Major contributing factors to coating quality from the powder mixture can include particle size distribution and particle shape. A mono-dispersed powder mixture is not ideal because of the packing and thus the density is lower. A more ideal powder mixture would be one that uses a range of particle sizes. The particle shape changes the flow and packing behavior of the mixture. As previously reported, more spherical shapes can be ideal for flow and packing, while irregular and jagged shapes can inhibit flow and dense packing.Complex Concentrated Alloys

[0094] The HEA field was dominated by configurational entropy, single-phase, and solid solution alloys. The HEA definition further restricted alloys to 5 or more principal elements, even though interesting results were being obtained in concentrated alloys with only 3 or 4 principal elements. Thus, the CCA definition was created to identify these concentrated alloys as a type of multi-component alloy that has no single, dominant element present. This definition includes every alloy that qualifies as an HEA and many alloys outside of the definition of an HEA, no longer being limited to a single microstructure or minimum of elements. Similar to HEAs, CCAs can possess a unique combination of properties, such as high strength, wear resistance, and corrosion resistance. The compositional distinction between conventional alloys, high entropy alloys, and complex concentrated alloys has been described, with the conventional alloys greatly favoring a single component with comparatively low alloying, where the complex concentrated alloys show a much more even mixture between each component, and high entropy alloys show a nearly equi-atomic composition.H13 Steel

[0095] H13 steel is a hot working tool steel, used commonly for forging dies, punches, and other parts that can withstand high temperatures while retaining strength. The high temperature conditions of forging can cause thermal fatigue and the materials that are being forged can cause mechanical fatigue. The dies were forged from high silicon steels, which can lead to abrasion on the die surface. Laser processing can alter the microstructure of H13 steel, changing the properties. Laser processing often produces 3 regions of microstructural change. The melt region has fully melted and recrystallized, resulting in austenitic dendrites with carbides and carbon-enriched ferrite. The partial melt region is not as affected by heat as theDOCKET NO 921402-2030melt region and largely includes coarse austenite, ferrite, martensite, and carbides. The heat affected zone which has experienced no melting, just solid-state reheating is composed of fine carbides and tempered martensite. These regions are all formed from thermal and consequently microstructural changes in the substrate, which is composed of austenite, martensite, and fine carbides.Previous Research

[0096] Various embodiments of the present disclosure build upon previous studies and follow similar powder processing routes and laser coating parameters which were determined to create an optimal coating on die steels. In various embodiments of the present disclosure, an Fe₀.₄₀₋ₓCo₀.₂₀₊ₓNi₀.₂₀Cr₀.₁₀Ti₀.₀₆Al₀.₀₄ CCA system was selected where x varies from 0, 5, 10, 15, and 20 at%. These alloys were prepared by mixing metallic powders, spraying a slurry containing these metallic powders onto a H13 steel die head surface, and then performing a laser surface treatment to produce a laser coating on a H13 steel die head. The structure, hardness, thermal stability, and wear resistance were investigated using scanning electron microscopy (SEM), X-ray diffraction (XRD), synchrotron radiation X-ray diffraction (SR-XRD), Vickers hardness testing, and in operando industrial wear testing.Experimental SetupPowder Preparation and Characterization

[0097] Table 1 shows the elemental composition in atomic percent of the two steel substrates. Table 2 shows the elemental composition in atomic percent of each CCA mixture. The Fe₀.₄₀₋ₓCo₀.₂₀₊ₓNi₀.₂₀Cr₀.₁₀Ti₀.₀₆Al₀.₀₄ CCAs are in at.%. These CCAs will be referred to as Fe(40), Fe(35), Fe(30), Fe(25), and Fe(20) respectively. The CCA system was selected based on a previous study on a promising laser-coated HEA with a similar composition and on modified Hume-Rothery rules reported for predicting the properties of HEAs. All experimental testing was also performed on uncoated H13 steel for comparison.

[0098] Table 1. Composition of FXT2 and H13 steel.at% Cr Mo Si Ni V Mn C Al Fe H13 4.88% 1.22% 1.10% 0% 1.03% 0.45% 0.36%.05% Bal.FXT2 1.15% 0.50% 0.25% 0.90% 0.07% 0.85% 0.50% 0% Bal.

[0099] Table2. Composition of Fe(40), Fe(35), Fe(30), Fe(25), and Fe(20) CCAs in atomic percent.DOCKET NO 921402-2030at% Fe Co Ni Cr Ti Al Fe(40) 40% 20% 20% 10% 6% 4% Fe(35) 35% 25% 20% 10% 6% 4% Fe(30) 30% 30% 20% 10% 6% 4% Fe(25) 25% 35% 20% 10% 6% 4%Fe(20) 20% 40% 20% 10% 6% 4%

[0100] The modified Hume-Rothery rules were used to predict the stability of a solid solution and the ductility of the material. A solid solution is predicted using the entropic consideration ( / 2) and atomic size consideration (<5). The entropic consideration can be calculated with Equations 2-5:Ω = (T_m ΔS_mix) / (|ΔH_mix|) (Equation 2) T_m = Σⁿᵢ₌₁ cᵢ(Tₘ)ᵢ (Equation 3) ΔS_mix = -R Σⁿᵢ₌₁ cᵢlncᵢ (Equation 4)(Equation 5) Ω is the entropic consideration, it is calculated with the melting temperature (Tₘ), entropy of mixing (ΔSₘᵢₓ), and enthalpy of mixing (ΔHₘᵢₓ). cᵢ is the atomic fraction of each component and ΔH^mix_AB is the binary enthalpy of mixing between two elements.

[0101] The atomic size consideration (5) can be calculated with Equation 6:δ = √(Σⁿᵢ₌₁ cᵢ(1 - rᵢ / r̄)²) (Equation 6)cᵢ is the atomic fraction of each component and rᵢ is the atomic radius of each component.

[0102] The valence electron consideration (VEC) is used to predict the ductility of the material. It can be calculated with Equation 7:VEC - (Equation 7) ci is the atomic fraction of each component and Vtis the number of valence electrons of each component.

[0103] A solid solution is predicted under the conditions that Q>1.1 and <5<6.6%. A ductile material is predicted under the condition that VEC < 4.4.DOCKET NO 921402-2030

[0104] Tables 3 and 4 show the values needed to calculate the results of the modified Hume-Rothery rules of mixing. Table 3 shows the heat of mixing (eV / atom) for each pair of elements. Table 4 shows the crystal structure, atomic radius (pm), melting temperature (°K), and the valence electrons of each element. The predicted properties of the alloys Fe(40), Fe(35), Fe(30), and Fe(25) are shown in Table 5.

[0105] Table 3. Mixing enthalpies relative to phase separation of constituent elements in CCA.mixing enthalpies(AHmix [meV / atom]) Fe Ni Cr Co Al Ti Fe 0 -97 -8 -60 -369 -418 Ni 0 -30 -21 -677 -435 Cr 0 5 -138 -372 Co 0 -629 -386 Al 0 -428Ti 0

[0106] T able 4. Modified Hume-Rothery rules of mixing calculation variables of constituent elements in CCA.Element Crystal @RT At. Radius (pm) Tm [K] ValenceFe BCC / FCC 126 1811 8Ni FCC 124 1728 10Cr BCC 128 2180 6Co HCP 125 1768 9Al FCC 143 933.5 3Ti HCP 146 1941 4

[0107] Table 5. Calculated Hume-Rothery rules-of-mixing properties of CCA alloys.CCA (40) CCA (35) CCA (30) CCA (25)Δ 4.62 4.64 4.65 4.67ΔSₘᵢₓ 12.8 13.0 13.1 13.0DOCKET NO 921402-2030Tm(K) 1795 1793 1791 1789Ω 1.10 1.11 1.12 1.13Γ 0.85 0.85 0.85 0.85VEC 7.96 8.01 8.06 8.11

[0108] The powders used for the CCA coatings were characterized using XRD, SEM, and particle size analysis. XRD on the powders was performed using a Rigaku Ultima III XRD machine, where a defining slit of 5 mm, a 2θ angle of 20° to 90°, and a speed of 2° per minute and a step size of 0.05° were used. SEM imaging was performed using a Hitachi TM3030plus for the powder mixtures and a FEI Quanta 200 Environmental SEM for the images of the coating interface. The powder diameter dispersion was measured using a Microtrac MRB. CALPHAD Simulations

[0109] Before creating the coatings on the steel substrates, the thermodynamics of each CCA composition were modeled using the CALPHAD software with THEA5 HEA database. To model the effect of dilution, the simulation modeled the compositional gradient in the coating from CCA to substrate at a constant temperature. The CALPHAD software was used to generate phase distribution graphs with respect to percent dilution from the pure CCA to pure H13 steel.Sample Preparation and Characterization

[0110] H13 and FXT2 steels were chosen as substrates for their prevalence as die materials. H 13 steel was donated from Cincinnati, OH, USA and FXT2 steel was donated from Chicago, IL, USA. The FXT2 die was not explored due to the die’s size and weight making it incompatible with the laser processing machine. To use the larger FXT2 die, a similar process may be used; however, a laser processing machine with a static stage and large chamber can be required. A repurposed H13 die head was sectioned using electrical discharge machining (EDM) to form circular cross sections with a thickness of ~5 mm. Two additional H13 steel die heads were donated for final laser coatings and in operando industrial testing. The process for forging die preparation was based on the process used by Wall et al. The vacuum free environment made the laser cladding process more cost- and time-efficient. The forging dies and the testing coupons were then sandblasted with coarse steel grit to coarsen the surface and improve the coating adherence. The powder mixtures were suspended in liquid binderDOCKET NO 921402-2030and reducer to create a spreadable slurry which was then spread onto the dies and coupons, similar to previous studies. This powder mixture was allowed to dry for over 8 hours to allow for water evaporation. The laser scanned across the surface of the die, melting the powder mixture onto the die head. This process of spreading slurry, drying, and laser scanning was repeated 3 times until a sufficient coating thickness was achieved. Two H13 die heads and two sacrificial H13 samples were prepared for laser cladding. The die heads were taller than the samples, which would cause the laser focus to be different and require different laser parameter settings. To remediate the focus problem, a metal stage of similar height was created. The sacrificial samples were put onto this metal stage, thus leveling the surfaces of both the die head and sacrificial samples.

[0111] The laser parameters were based on previous studies that used a beam spot diameter of 6.0 mm, beam traverse speed of 100 mm / s, and an Argon-filled glass chamber to protect the melt pool from oxidation. After the dies and tiles were coated with a sufficiently thick layer of CCA, the sacrificial tiles were cut using a MTI STX-202A diamond wire saw. The cross sections of the alloys were characterized using a FEI Quanta 200 ESEM with EDS. Elemental and phase mapping of the cross-sectional area of each laser-coated alloy was performed to image the microstructure and identify the elemental segregation and phase formation near the surface, heat affected zones, and interface to study how well the CCA adhered to the two steels. Although not presented here, preliminary XRD was performed on the CCA laser-coated samples using a Rigaku Ultima III to identify different phases present in the laser-coating samples. A defining slit of 5 mm was used, and the samples were scanned using a 2θ angle of 20° to 90° with a speed of 2° per minute and a step size of 0.05°. Based on the preliminary XRD, high-energy synchrotron radiation XRD measurements were collected at the Sector 6-ID-D beam line of the Advanced Photon Source (APS) at Argonne National Laboratories. A beam energy of 86.9 keV and a beam size of 200 × 200 μm2were used. Ex situ SR-XRD experiments were performed on H13 and FXT2 Fe0.40-xCo0.20+xNi0.20Cr0.10Ti0.06Al0.04CCA at 700-900 W.

[0112] Vickers hardness testing was performed using a Buehler Macromet 1 Vickers hardness testing machine on the CCA coated samples for each laser fluence setting using a normal load of 0.1 N with a dwell time of 10 seconds. For each laser power setting, 55 measurements were collected in an 11 x 5 grid to determine an average hardness value. The Vickers hardness testing was performed at various depths across the metal coating cross section to determine the strength at each depth of the coating and substrate. A model of thisDOCKET NO 921402-2030Vickers hardness indentation pattern is shown in FIG. 1. Hardness measurements take place throughout each layer of the coating 20 μm apart to ensure no influence from the previous indent. The hardness of the coating, interface, and heat affected zones were measured to determine the effectiveness of the coating layers. The average Vickers hardness for this specific H13 tool steel has been reported as -520 kgf / mm2previously.

[0113] After using simulation and rule-of-mixing calculations to select the alloys compositions, four compositions were explored. Each alloy had a composition of Fe0.40-xCo0.20+xNi0.20Cr0.10Ti0.06Al0.04, with the iron and cobalt varying in mass while the nickel, chromium, titanium, and aluminum were kept constant. The variance of iron and cobalt was used to determine the most ideal wear resistant and high temperature resistant alloy. The CCA compositions were labeled by their iron content, with 40 at.% iron being the Fe(40) alloy, 35 at.% iron being Fe(35), 30 at.% iron being Fe(30), and 25 at.% iron being Fe(25).

[0114] The first round of coatings involved laser coating the Fe(40) composition with varying laser power (700 W, 800 W, and 900 W) to determine the ideal laser power. Using the ideal laser power, the next set of coatings used varying coating compositions (Fe(25), Fe(30), and Fe(35)) at a constant laser power of 900 W to determine the optimal composition for the CCA.

[0115] The ideal laser power setting was determined by analyzing the interface between the coating and the substrate to identify mixing, coating adhesion, and coating porosity. The ideal coating compositions were determined by performing hardness testing along the cross section, creating a hardness map of the material as a function of depth.

[0116] Two coated and polished dies were sent for industrial use to evaluate the practical effects of the laser cladding process. The Fe(30) die was returned after being used to create 21,000 parts, which is already 2,000 parts more than a typical die can obtain before needing repair, this die was evaluated before being returned for continued testing.ResultsCALPHAD Simulation

[0117] The CALPHAD simulation results are presented in FIGS. 2-5, where the percentages of phases is plotted against the dilution of the alloy coating to the bulk H13 steel composition. Each simulation was conducted under isothermal conditions at 600 °C, 800 °C, or 1000 °C for each alloy composition. These figures illustrate the depth-dependent compositional profiles, showing the transition from alloy coating surface composition to bulkDOCKET NO 921402-2030H13 steel composition due to interfacial mixing. FIG. 2A simulates the compositional transition from the Fe(25) alloy to bulk H13 steel at 600 °C, which exhibits a complex multiphase region dominated by BCC and FCC phases. These become dominated by a single BCC phase when the alloy becomes substantially diluted by the H13 substrate. FIG. 2B shows the behavior at 800 °C which appears similar to FIG. 2A; however, the FCC phase is more stable, transforming into the final BCC phase only at greater distance from the surface. FIG. 2C shows that at 1000 °C, the FCC phase dominates the alloy with some BCC present.

[0118] FIG. 3A simulates the compositional transition from the Fe(30) alloy to bulk H13 steel at 600 °C, which exhibits a complex multiphase region that becomes dominated by a single BCC phase. FIG. 3B shows that at 800 °C, the FCC phase dominates the alloy, eventually becoming BCC. FIG. 3C shows that the FCC phase at 1000 °C dominates the alloy only balancing with the BCC phase at full dilution but still retaining substantial FCC composition.

[0119] FIG. 4A shows the compositional transition from the Fe(35) alloy to bulk H13 steel at 600 °C. The complex multiphase region shows greater stability of a second FCC phase at no dilution. FIG. 4B shows the gradual domination of the BCC phase at the substrate. FIG. 4C shows that the decrease in cobalt content has decreased the stability of the FCC phase at full dilution, leading to a greater amount of the final BCC phase at 1000 °C.

[0120] FIG. 5A shows the compositional transition from the Fe(40) alloy to bulk H13 steel at 600°C. The multiphase region shows even greater stability of the second FCC phase. At 800°C shown in FIG. 5B, the second FCC phase dissipates in favor of the first FCC phase and the BCC phase. FIG. 5C shows significant destabilization of the FCC phase at full dilution at 1000°C.Preliminary Study

[0121] SEM images of the Fe(40) CCA coatings with varying laser powers are shown in FIG. 6. The left column shows a magnified image of the CCA coating to H13 steel substrate interface for a given laser fluence, the right column shows the EDS map of iron in this interface. These three sets of images show the effect of varying laser fluence on the laser processed coating. The CCA and H13 interface shows optimal adhesion. No interfacial separation is observed, indicating that the CCA coating and H13 substrate were sufficiently heated to mix and adhere. The EDS maps of the 700 W and 800 W laser powers show a clear compositional difference between the coating and the substrate, while the 900 W laser power shows a much more subtle transition, indicating that the 900 W laser power resulted in greater mixing. These results indicate that the 900 W laser power was sufficient to heat the substrate metal andDOCKET NO 921402-2030promote mixing with the coating. No cracks were observed in the material; however, holes were observed indicating porosity in the coatings made with the 700 W and 800 W laser powers.

[0122] Using the 900 W laser power from the previous test, the composition of the coating was varied between the Fe(25), Fe(30), and Fe(35) compositions. The interfaces of these coatings are shown in FIGS. 7A-7C. The processing for these conditions was identical to the previous tests, so no significant differences in mixing were expected. The Vickers hardness across the coating interface was measured at 0.1 N of force. FIG. 8 shows the hardness results of the Fe(25), Fe(30), and Fe(35) coatings on H13 steel. There is variance within the hardness due to porosity within the coating which decreases with repeated heating. The Fe(25) exhibits the lowest hardness, followed by the Fe(35) coating, and finally with the Fe(30) coating which exhibits the greatest hardness. The red line is the baseline hardness of bulk H13 steel, which is slightly exceeded by the Fe(30) and Fe(35) coatings.Powder Characterization

[0123] After down-selection from the preliminary study, the particle size distributions of the Fe(30) and Fe(35) powder mixtures were analyzed and shown in FIGS. 9A and 9B. The broad powder distributions observed in FIGS. 9A and 9B are better suited to dense packing than a narrow powder distribution. A homogeneous powder size distribution results in sub ideal packing; this variable is easily altered by using different powder sizes. The powder distribution is slightly broader for the Fe(30) alloy in FIG. 9A than for the Fe(35) alloy in FIG.9B.

[0124] FIGS. 10A-10F show the SEM images of the metal powders used to make the CCA before mixing. The powder images show a variety of powder sizes, which is consistent with the broad powder size distribution measurements. As illustrated in FIGS. 10A-10D, the Fe, Co, Cr, and Ni powders are all within the same length scale, respectively; however, the Al and Ti powders in FIGS. 10E and 10F are an order of magnitude larger which contributes to improved packing due to heterogeneous powder sizes. FIGS. 11 A-11 D show the powder size variance in the CCA powders after mixing. The various sizes of powders shown in the mixed images are consistent with the measured powder size distribution. The large-scale images for the Fe(30) and Fe(35) alloys in FIG. 11 B and 11 D, respectively, show that there are large and small particles mixed together while small scale images for the Fe(30) and Fe(35) alloys in FIG. 11A and 11B, respectively, show that the small particles fill in the gaps.SEM and EDSDOCKET NO 921402-2030

[0125] FIGS. 12A-12H show the EDS maps of the Fe(30) and Fe(35) alloy depositions. The layered images in FIG. 12A and 12E show the combined EDS maps of all elements present. The Fe, Co, and Ni EDS maps in FIGS. 12B-12H clearly show the coating layers and the transition to the bulk H13 steel. A distinct separation can be observed between the coating and substrate with some mixing of the coating from the substrate. There are notable layers in the composition gradient which is a result of the three depositions and reheating processes.

[0126] FIG. 13A shows the SEM image of the Fe(35) alloy after polishing to remove surface roughness. This is representative of the die sent for testing. Based on the Fe and Cr EDS maps shown in FIG. 13B and 13C, the final coating thickness for the forging die is slightly greater than 100 pm.X-ray Diffraction

[0127] FIGS. 14A and 14B show the 2D DeBye-Scherrer XRD patterns and corresponding integrated and normalized 1-D XRD lineouts with identified (hkl) diffraction peaks for the (FIG.14A) Fe(30) and (FIG. 14B) Fe(35) coatings. The crystal structure and diffraction planes are labeled above each peak.

[0128] As illustrated in FIG. 14A, the Fe(30) alloy (0 pm depth) surface is largely composed of an FCC phase, which gradually decreases until it disappears completely around a depth of 200 pm. The FCC phase exhibits peak splitting at the (111) and (200) planes, indicating the presence of 2 different FCC phases. The bulk H13 steel (300 pm depth) shows only a BCC phase, which is typical of a tempered martensite. The BCC phase is prevalent throughout the coating up until about 40 pm from the surface. A small amount of peak splitting is observed, indicating the potential for a small amount of the BCT martensite phase being present. The BCC d-spacing is also observed to shift slightly down from the bulk H13 steel to the Fe(30) alloy surface, which is likely due to Co replacing Fe atoms in the lattice, thus increasing the lattice parameter.

[0129] Accompanying 2D DeBye-Scherrer XRD patterns show the grain structure at 0 pm, 80 pm, 160 pm, 240 pm, and 320 pm. FIG. 14A shows the surface being a directionally oriented FCC dominated structure. This begins transitioning to a fine-grained BCC structure at 40 pm. By 200 pm the structure has become mostly a weakly oriented BCC, which transitions to a randomly oriented and fine-grained BCC structure by 300 pm in depth.

[0130] As illustrated in FIG. 14B, the Fe(35) alloy (0 pm depth) surface is also largely composed of an FCC phase, which gradually decreases until it disappears around 290 pm. Stronger FCC peak splitting at the (111) and (200) peaks are observed in comparison to that of the Fe(30) alloy. The bulk H13 steel (300 pm depth) shows only a BCC phase, which isDOCKET NO 921402-2030typical of a tempered martensite, like that observed in the Fe(30) alloy. This BCC phase shifts down slightly going from the bulk H13 steel to the Fe(35) alloy surface and disappears completely around 120 pm in depth.

[0131] As illustrated in FIG. 14B, accompanying 2D DeBye-Scherrer XRD patterns for the Fe(35) alloy coated sample show the grain structure at 0 pm, 80 pm, 160 pm, 240 pm, and 320 pm. Like the Fe(30) alloy coating, the Fe(35) alloy coating exhibits a surface that shows a directionally oriented FCC structure, which transitions to a randomly oriented and fine grained BCC structure by 300 pm in depth, which is typical of a tempered martensite H13 steel.Hardness Testing

[0132] FIGS. 15A-15C show the hardness map of the Fe(30) and Fe(35) alloy interfaces with H13 steel. The hardness of the coated surface is low but increases with deeper layers. The hardness of the H13 substrate is the straight, dotted line at 520 HV0.1. There are 3 distinct hardness regions as a result of the 3 laser coatings. A subsequent laser coating process causes reheating of the previous layer, partially melting it, the hardness regions come from the layering and remelting.

[0133] Laser cladding causes pores within the surface structure, causing a reduction in hardness compared to what is expected. Reheating due to subsequent laser processing reduces some of these pores, increasing the hardness of the alloy.Optical Microscopy

[0134] The Fe(30) coated die was in service for 21,000 parts. Dies are typically cycled out for replacement or repairs at 19,000 parts. Each part undergoes three forging processes, starting with a steel cylinder. Upsetting deforms the steel cylinder face, gathering the material at the face. This gathered material is then forged into a rectangular shape with excess material spilling around it called the flash. Lastly, the flash is cut off from the rectangular shape, leaving the finished part. The forged part and final part are shown in FIG. 16. FIGS. 17A-17E show the worn die head at increasing magnifications. FIG. 17A shows the worn die surface after 21,000 parts. FIG. 17B shows a more magnified image of the deformation region which exhibits 3 distinct regions. FIG. 17C shows a compressive stress region, FIG. 17D shows a shear stress region, and FIG. 17E shows a compressive stress region. The Fe(30) coated die has exceeded the average lifetime of dies used in this process and is still viable for further use, showing that the resurfacing and coating process has improved die life.DiscussionDOCKET NO 921402-2030

[0135] The preliminary work to identify the most ideal laser parameters showed the 900 W power to be the most ideal. The porosity within the coating decreased relative to increasing laser power and the mixing between the coating and substrate increased with laser power. The lower porosity, greater adhesion, and greater mixing offered by the 900 W laser power were ideal, so this was chosen as the laser power setting for future coatings. The Fe(30) and Fe(35) alloy coatings exhibited the most promising properties, so these compositions were used for the forging die heads. Based on these results, the final coating parameters for the dies were coated with the Fe(30) and Fe(35) alloys processed with a 900 W laser for the ideal combination of mixing, adhesion, hardness, and density.

[0136] The particle size distribution observed in the CCA powder mixture is broad, which avoids the low packing density from a homogeneous particle size distribution; however, the packing density may be further improved with a greater range of particle sizes or the use of two homogeneous but different particle sizes to create a bimodal distribution rather than a broad distribution.

[0137] The hardness of the coating interface was sectioned into four regions. The substrate and 3 regions within the coating were a result of the different depositions, reheating of the previous layers from another deposition, and dilution from each layer. These also exhibited different properties due to the reduction of pores from reheating of the layers, so the outermost layer exhibited the highest porosity; thus, it is recommended that the coating be reheated without applying another layer to reduce porosity and improve performance. Based on SEM images and EDS maps, the coating exhibited dilution from the substrate. While this result indicated good mixing and a good interface, the properties of the alloy differed from the pure CCA that would be observed on the surface. After deposition, the die was polished until it was smooth, so the surface of the polished die exhibited a more diluted alloy than the surface of the unpolished die.

[0138] The CALPHAD simulations predicted a complex surface structure composed of a BCC phase and one or two FCC phases. These FCC and BCC phases generally disappeared with the transition from the alloy surface to the bulk H13 steel, which showed a different BCC structure. Increasing the Co content of the alloys increased the stability of the initial and most dominant FCC structure. At 600 °C, this complex multiphase region then transitions into the BCC dominated substrate with trace amounts of other phases, notably BCT. The domination of FCC phase in the 800 °C and 1000 °C predictions are a result of austenitic transformation. The austenitic transformation range is within 800 °C and 1000 °C, this is why there is austeniteDOCKET NO 921402-2030present in the 800 °C predictions but dominates in the 1000 °C simulations. Increasing iron content is shown to stabilize the BCC phase, resulting in a lower austenite composition.

[0139] The initial structure of the H13 die is BCT martensite and BCC ferrite. Reheating of the alloy from the laser treatment process causes the metastable martensite to break down into stable ferrite.

[0140] XRD showed that the alloy coatings were observed to transition from an FCC surface structure to a BCC structure for the bulk H13 steel. Increasing the Co content of the alloys increased the stability of the FCC structure, which is different from predictions from CALPHAD. The Fe(35) FCC phase in FIG. 14B shows some peak splitting, indicating two FCC phases. This agrees with the predictions from CALPHAD. This peak splitting is exacerbated in the Fe(30) FCC phase in FIG. 14A. Both coatings in FIGS. 14A and 14B show the surface of the coating being almost completely FCC. This conflicts with the CALPHAD predictions because the alloy was not processed in slow, equilibrium conditions, the high processing temperature and high cooling rate resulted in retained FCC rather than a mixture of FCC and BCC phases. The surface being composed of FCC phases is promising for strain hardening of the coating, increasing hardness as the die experiences stress during forging.

[0141] The diffraction patterns in FIGS. 14A and 14B show that the two alloys transition crystal structure at different depths due to slight differences in coating thickness. The Fe(30) coating largely transitions into BCC at 160 pm while the Fe(35) coating largely transitions into BCC at 240 pm. This difference in coating thickness and transformation depth is a result of the quickened, but less consistent, slurry application process.

[0142] The tested and returned die, which was coated with Fe(30) alloy, showed the three different modes of deformation which corresponded to the three forging processes that the die underwent. The upsetting process involves striking a steel rod to spread material for the later processes; this creates the circular compressive stress in FIG. 17E. The forging process forges the gathered material from the upsetting phase into the shape of the part with an excess flash, the friction from the deformation of this process causes the shear stress in region B. The formation of the flash from the excess material causes the compressive stress deformation in region A.

[0143] After inspecting the wear on the Fe(30) die head, the die was shipped back for continued use to produce parts, since it was deemed fit for continued service. The Fe(30) die showed improved durability over the standard H13 steel dies and has improved the repair process for worn H13 steel dies.ConclusionsDOCKET NO 921402-2030

[0144] Various complex concentrated alloys and laser parameters were evaluated for their hardness, adhesion, dilution, and microstructure. Based on the preliminary results and CALPHAD predictions, two complex concentrated alloys (Fe0.35Co0.25Ni0.20Cr0.10Ti0.05Al0.04and the Fe0.30Co0.30Ni0.20Cr0.10Ti0.06AI0.04) were selected and processed based on optimal laser parameters for die coating for industrial testing. The Fe0.35Co0.25Ni0.20Cr0.10Ti0.06AI0.04 and the Feo 30Co0.30Ni0.20Cr0.10Ti0.06AI0.04 complex concentrated alloys were applied to a resurfaced forging die and sacrificial tiles. The coated dies were sent to be used to forge parts and to compare with the existing dies which typically create 19,000 parts before requiring repair or replacement. The sacrificial tiles were tested and characterized using Vickers hardness, SEM, EDS, and XRD. The raw powders used to compose the CCAs were analyzed for their size and morphology. The microstructure and dilution were characterized using EDS and XRD, showing that the coating starts as a complex multiphase alloy consistent with simulations, which gradually becomes diluted into a BCC dominated alloy, reflective of the simulated phase distribution. The coated Fe(30) die was sent back for analysis after forging 21,000 parts and was deemed still viable for use, showing that the process had improved the repair process and the die head’s durability. The application of CCA coatings using laser cladding is a promising option for extending durability and lifetime of parts requiring high wear resistance such as forging dies.Recommendations

[0145] A more densely packed powder mixture can be accomplished by using two sets of homogeneous powder sizes rather than a broad range of powder sizes. A more consistent method of mixing and applying the powder slurry can yield a better coating layer consistency. Due to the observed reduction in porosity with deeper coating layers due to reheating, one method of reducing porosity in the coating would be to perform another laser process on the die head after coating without any additional CCA to reheat the existing layers.References for Example 1

[0146] Ref. 1 T. Byrer, S. Semiatin, D. Vollmer, “Forging Handbook” Forging Industry Association, ISBN: 0-87170-194-4

[0147] Ref. 2 Yeh, Jien-Wei & Chen, S.-K & Lin, Su-Jien & Gan, Jon-Yiew & Chin, Tsung-Shune & Shun, Tian & Tsau, C.-H & Chang, SY. (2004). “Nanostructured High-Entropy Alloys with Multiple Principal Elements: Novel Alloy Design Concepts and Outcomes.” Advanced Engineering Materials. 6. 299 - 303. 10.1002 / adem.200300567.

[0148] Ref. 3 Rajiv S. Mishra, Ravi Sankar Haridas, Priyanshi Agrawal, “High entropy alloys - Tunability of deformation mechanisms through integration of compositionalDOCKET NO 921402-2030and microstructural domains”, Materials Science and Engineering: A, Volume 812, 2021, 141085, ISSN 0921-5093, https: / / doi.org / 10.1016 / j.msea.2021.141085.

[0149] Ref. 4 Cantor, B„ Chang, I. T. H„ Knight, P. & Vincent, A. J. B. “Microstructural development in equiatomic multicomponent alloys” Mat. Sci. Eng. A 375-377, 213–218 (2004).

[0150] Ref. 5 S. Gorsse, D. B. Miracle, and O. N. Senkov, “Mapping the world of complex concentrated alloys,” Acta Mater, vol. 135, pp. 177–187, 2017, doi: 10.1016 / j.actamat.2017.06.027.

[0151] Ref. 6 S. Gorsse, J. P. Couzinie, and D. B. Miracle, “From high-entropy alloys to complex concentrated alloys,” C R Phys, vol. 19, no. 8, pp. 721–736, 2018, doi: 10.1016 / j.crhy.2018.09.004.

[0152] Ref. 7 O. N. Senkov, J. D. Miller, D. B. Miracle, and C. Woodward “Accelerated exploration of multi-principal element alloys with solid solution phase” Entropy 2014, 16, 494-525; doi: 10.3390 / e16010494

[0153] Ref. 8 D. B. Miracle, O. N. Senkov, “A critical review of high entropy alloys and related concepts” Acta Materialia, Volume 122, 2017, Pages 448-511, ISSN 1359-6454, https: / / doi.org / 10.1016 / j.actamat.2016.08.081.

[0154] Ref. 9 Dahotre, Narendra B. " Laser surface engineering: recent developments are providing more efficient, reliable, and cheaper lasers for cost-effective surface engineering." Advanced Materials & Processes, vol. 160, no. 7, July 2002, pp.35+. Gale Academic OneFile, link.gale.com / apps / doc / A89160570 / AONE?u=anon~7bc7782d&sid=googleScholar&xid=174 89c36. Accessed 3 Dec. 2025.

[0155] Ref. 10 P. W. Leech, “Laser surface melting of a complex high alloy steel,” Mater Des, vol. 54, pp. 539–543, 2014, doi: 10.1016 / j.matdes.2013.08.060.

[0156] Ref. 11 Z. Yan et al., “Effect of thermal characteristics on distortion in laser cladding of AISI 316L,” J Manuf Process, vol. 44, pp. 309–318, Aug. 2019, doi: 10.1016 / j.jmapro.2019.06.011.

[0157] Ref. 12 N. Ur Rahman et al., “Development and characterization of multilayer laser cladded high speed steels,” Addit Manuf, vol. 24, pp. 76–85, Dec. 2018, doi: 10.1016 / j.addma.2018.09.009.

[0158] Ref. 13 L. Reddy, S. P. Preston, P. H. Shipway, C. Davis, and T. Hussain, “Process parameter optimisation of laser clad iron based alloy: Predictive models ofDOCKET NO 921402-2030deposition efficiency, porosity and dilution,” Surf Coat Technol, vol. 349, pp. 198–207, Sep.2018, doi: 10.1016 / j.surfcoat.2018.05.054.

[0159] Ref. 14 W. H. Jiang and R. Kovacevic, ‘‘Laser deposited TiC / H13 tool steel composite coatings and their erosion resistance,” J Mater Process Technol, vol. 186, no.1–3, pp. 331–338, 2007, doi: 10.1016 / j.jmatprotec.2006.12.053.

[0160] Ref. 15 F. G. Coury et al., “Phase equilibria, mechanical properties and design of quaternary refractory high entropy alloys,” Mater Des, vol. 155, pp. 244–256, 2018, doi: 10.1016 / j.matdes.2018.06.003.

[0161] Ref. 16 J. Li, Y. Huang, X. Meng, and Y. Xie, “A Review on High Entropy Alloys Coatings: Fabrication Processes and Property Assessment,” Adv Eng Mater, vol.1900343, no. 92, pp. 1–27, 2019, doi: 10.1002 / adem.201900343.

[0162] Ref. 17 Y. Shi, B. Yang, and P. K. Liaw, “Corrosion-resistant high-entropy alloys: A review,” Metals (Basel), vol. 7, no. 2, pp. 1–18, 2017, doi: 10.3390 / met7020043.

[0163] Ref. 18 L. J. Santodonato et al., “Deviation from high-entropy configurations in the atomic distributions of a multi-principal-element alloy,” Nat Commun, vol.6, 2015, doi: 10.1038 / ncomms6964.

[0164] Ref. 19 Liping Guo, Hanjie Liu, Hongze Wang, Qianglong Wei, Yakai Xiao, Zijue Tang, Yi Wu, Haowei Wang, “Identifying the keyhole stability and pore formation mechanisms in laser powder bed fusion additive manufacturing” Journal of Materials Processing Technology, Volume 321, 2023, 118153, ISSN 0924-0136, https: / / doi.org / 10.1016 / j.jmatprotec.2023.118153

[0165] Ref. 20 M. T. Wall et al., “Laser-coated CoFeNiCrAITi high entropy alloy onto a H13 steel die head,” Surf Coat Technol, vol. 387, Apr. 2020, doi: 10.1016 / j. surfcoat.2020.125473

[0166] Ref. 21 N. Ley, S. S. Joshi, B. Zhang, Y. H. Ho, N. B. Dahotre, and M. L. Young, “Laser coating of a CrMoTaWZr complex concentrated alloy onto a H13 tool steel die head,” Surf Coat Technol, vol. 348, pp. 150–158, Aug. 2018, doi: 10.1016 / j. surfcoat.2018.02.038

[0167] Ref. 22 Seyed Amir Farzadfar, Martin J. Murtagh, Navin Venugopal, “Impact of IN718 bimodal powder size distribution on the performance and productivity of laser powder bed fusion additive manufacturing process” Powder Technology, Volume 375, 2020, Pages 60-80, ISSN 0032-5910, https: / / doi.org / 10.1016 / j.powtec.2020.07.092.DOCKET NO 921402-2030

[0168] Ref. 23 D. Huck-Jones, C. Langley, “Beyond particle size: Exploring the influence of particle shape on metal powder performance” Metal AM, https: / / www.metal-am.com / articles / the-influence-of-particle-shape-on-powder-performance-metal-3d-printing /

[0169] Ref. 24 M. C. Gao et al., “Thermodynamics of concentrated solid solution alloys,” Curr Opin Solid State Mater Sci, vol. 21, no. 5, pp. 238–251, 2017, doi: 10.1016 / j.cossms.2017.08.001.

[0170] Ref. 25 D. Miracle, B. Majumdar, K. Wertz, and S. Gorsse, “New strategies and tests to accelerate discovery and development of multi-principal element structural alloys,” Scr Mater, vol. 127, pp. 195–200, 2017, doi: 10.1016 / j.scriptamat.2016.08.001.

[0171] Ref. 26 X. Yang, Y. Lai, Z. Zhang, T. Zhang, X. Yao, F. Song, Y. Hou, H. Qi, H. Tang, “Microstructure evolution and mechanical properties of H13 steel produced by Selective Electron Beam Melting” Materials Characterization, Volume 203, 2023, 113053, ISSN 1044-5803, doi.org / 10.1016 / j.matchar.2023.113053.

[0172] Ref. 27 G. Telasang, J. Dutta Majumdar, G. Padmanabham, I. Manna, “Structure-property correlation in laser surface treated AISI H13 tool steel for improved mechanical properties” Materials Science and Engineering: A, Volume 599, 2014, Pages 255-267, ISSN 0921-5093, https: / / doi.org / 10.1016 / j.msea.2014.01.083.

[0173] Ref. 28 S. S. Joshi, S. Katakam, H. Singh Arora, S. Mukherjee, and N. B. Dahotre, “Amorphous Coatings and Surfaces on Structural Materials,” Critical Reviews in Solid State and Materials Sciences, vol. 41, no. 1. Taylor and Francis Inc., pp. 1–46, Jan. 02, 2016. doi: 10.1080 / 10408436.2015.1053602.

[0174] Ref. 29 Takeuchi, Akira & Inoue, Akihisa. (2005). “Classification of Bulk Metallic Glasses by Atomic Size Difference, Heat of Mixing and Period of Constituent Elements and Its Application to Characterization of the Main Alloying Element. Materials Transactions” - MATER TRANS. 46. 2817-2829. 10.2320 / matertrans.46.2817.

[0175] Ref. 30 Sheikh, Saad Ahmed et al. “Alloy design for intrinsically ductile refractory high-entropy alloys.” Journal of Applied Physics 120 (2016): 164902.

[0176] Ref. 31 “Data sheet hot work tool steel FX-Xtra®” Finkl Steel, May.2019, https: / / www.finkl.com / wp-content / uploads / 2019 / 05 / FX_EN_may19.pdf2. Example 2

[0177] There are eight main causes of die damage and wear that can lead to die failure. These include die material properties, die design, forging process parameters, surface treatments, types of damage, operational factors, residual stress, and heat treatment. VariousDOCKET NO 921402-2030embodiments of the present disclosure can allow for rapid assessment of a die, die-head coatings, die-head lubricants, and other similar die-head improvements for forging machines (e.g., machines configured for drop forging, press forging, upset forging, roll forging, precision forging, isothermal forging, and the like). Enabling faster assessment of die-heads and their coatings could enable faster adoption of new coating techniques such as laser engineered net shaping (LENS), direct energy deposition (DED), and other additive manufacturing (AM) processes due to the ability to test the materials more quickly on a small scale and at lower cost of materials and time. This could lead to extended die-head lifetime by allowing more rapid development of improved coatings. The faster assessment could also reduce time and costs associated with replacing or repairing worn or damaged die-heads.

[0178] Disclosed is a micro-scale forging apparatus comprising a hammering device and a die configured to removably couple to the hammering device, wherein the die comprises a punch and a plate, wherein the hammering device is configured to strike the plate with the punch. In various aspects, the hammering device can include a hydraulic press, one or more mechanical powered hammers and an electric motor, or one or more eccentric crank gears and a motor. A hydraulic press uses hydraulic pressure to generate a large compressive force and is based on Pascal’s Law, which states that pressure applied to a confined fluid is transmitted equally in all directions. A hydraulic press can apply small forces to a small piston to be converted into a much larger force on a larger piston. A mechanical press uses mechanical energy, typically generated by a flywheel, a crankshaft, or cam system, to apply force to a workpiece. A mechanical press can be used for stamping, forming, punching, forging, or in any process where high speed and repeatability are desirable.

[0179] FIG. 18 shows an example of a hydraulic press that can be used with a die to perform various method steps as described herein. In various examples, the dies of FIGS.19A-19H can be used to assess the dies and any coatings or lubricants applied to the dies. FIG. 20 shows example physical dimensions and properties of various dies used to perform various method steps as described herein. In some examples, application of high entropy alloys, application of complex concentrated alloys, thermal spraying, laser cladding, and / or nitriding can be used with the dies described herein to assess performance of various coatings and coating methods in extending the useful lifetime of a die.

[0180] It will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. Other aspects of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure disclosed herein. It is intendedDOCKET NO 921402-2030that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.

Claims

DOCKET NO 921402-2030ClaimsTherefore, at least the following is claimed:

1. A method of assessing a die for die repair, comprising:simulating forging by striking a plate with a punch a number of times; and evaluating a surface of the punch, the plate, or both.

2. The method of claim 1, wherein evaluating the surface of the punch, the plate, or both further comprises assessing the surface using one or more of optical microscopy, scanning electron microscopy, dilatometry, or energy dispersive spectroscopy.

3. The method of claim 1 or 2, further comprising evaluating the surface of the punch, the plate, or both prior to simulating forging.

4. The method of any one of claims 1-3, further comprising coating the surface of the punch, the plate, or both prior to simulating forging.

5. The method of any one of claims 1-4, wherein the number of times is based at least in part on an evaluation of the surface of the punch, the plate, or both.

6. The method of any one of claims 1-5, further comprising heating the punch, the plate, or both prior to simulating forging.

7. The method of any one of claims 1-6, further comprising applying a lubricant to the surface of the punch, the plate, or both prior to simulating forging.

8. A micro-scale forging apparatus, comprising:a hammering device; anda die configured to removably couple to the hammering device, wherein the die comprises:a punch; anda plate, wherein the hammering device is configured to strike the plate with the punch.

9. The micro-scale forging apparatus of claim 8, wherein the punch, the plate, or both are coated.DOCKET NO 921402-203010. The micro-scale forging apparatus of claim 8 or 9, wherein the die comprises one or more metals.

11. The micro-scale forging apparatus of any one of claims 8-10, wherein the die comprises H13 steel or FXT2 steel.

12. The micro-scale forging apparatus of any one of claims 8-11, wherein the punch has a diameter of approximately 200 pm to approximately 10 mm.

13. The micro-scale forging apparatus of any one of claims 8-12, wherein the punch, the plate, or both are coated with one or more complex concentrated alloys (CCA), one or more high entropy alloys (HEA), or a nitride coating.

14. The micro-scale forging apparatus of any one of claims 8-13, wherein the hammering device comprises a hydraulic press, one or more mechanical powered hammers and an electric motor, or one or more eccentric crank gears and a motor.

15. A method of assessing a die for die repair, comprising:forging a number of parts with the die; andevaluating a surface of the die.

16. The method of claim 15, wherein evaluating the surface of the die further comprises assessing the surface using one or more of optical microscopy, scanning electron microscopy, dilatometry, or energy dispersive spectroscopy.

17. The method of claim 15 or 16, further comprising evaluating the surface of the die prior to forging the number of parts.

18. The method of any one of claims 15-17, further comprising coating the surface of the die prior to forging the number of parts.

19. The method of any one of claims 15-18, wherein the number of parts is based at least in part on an evaluation of the surface of the die.

20. The method of any one of claims 15-19, further comprising heating the die prior to forging the number of parts.DOCKET NO 921402-203021. The method of any one of claims 15-20, further comprising applying a lubricant to the surface of the die prior to forging the number of parts.

22. The method of any one of claims 15-21, further comprising coating the surface of the die using one or more additive manufacturing processes, welding, plating, or a combination of any thereof.

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