Proceedings of the 13th World Conference on Titanium

Edited by: Vasisht Venkatesh, Adam L. Pilchak, John E. Allison, Sreeramamurthy Ankem, Rodney Boyer, Julie Christodoulou,
Hamish L. Fraser, M. Ashraf Imam, Yoji Kosaka, Henry J. Rack, Amit Chatterjee, and Andy Woodfield
TMS (The Minerals, Metals & Materials Society), 2016

GFM RADIAL FORGING MACHINES FOR THE TITANIUM MARKET

Robert Koppensteiner1, Martin Auer1, Brad Fair2
1GFM GmbH, Ennserstraße 14, 4403 Steyr, Austria
2American GFM Corporation, 1200 Cavalier Blvd, Chesapeake, Virginia USA

Keywords: Forging, Alloys, Applications

Abstract A process like radial forging therefore has to accommodate for the
proper deforming characteristic in addition to the geometrical
The use of titanium alloys is significant in industry. This places a aspect of forging.
greater emphasis on the processing of these alloys to obtain We will categorize, in the following, the forging into primary
certain metallurgical and functional characteristics. To this end, forging, intermediate billet forging and specific final forging
Radial Forging technology is well suited to support these applications, like for turbine blades and hip joints. Finally, we will
processing requirements. Because of the unique capabilities of the investigate the GFM radial forging applicability for powder
Radial Forging machine, forming of contoured components can be metallurgical titanium alloys.
accomplished for the requirements of many industries including
aerospace, energy generation and medical. Radial forging is a
highly productive and versatile technology for the processing of Primary Forging
titanium alloys and can be an integral part in the processing of
components that utilize titanium alloys. The primary forging is considered to be the first forming step in a
production sequence. In the case of long products it starts with the
The focus in this paper is the application opportunities and ingot and the product is a billet.
optimization tools available with GFM Radial forging for primary The well-established process route starts with homogenization and
titanium and titanium alloys forging as well as preform forging. forging on open-die presses in various passes and reheats. The
final shape and forging is done frequently on radial forging
machines (see fig. 1a) as it is a more economical product. The
Introduction surface finish and straightness of the GFM product is superior to
the forged bar from a forging press [5].
Radial forging is a well-known incremental forming process [1,2].
Radial forging is often referred to as, and confused with, rotary As the required forging forces are about 40% less for 4 hammer
forging. The term rotary forging is used due to the fact that in radial forging compared to the open-die press forging, there is the
many operations the work piece is rotated during the forging potential to direct forging on a GFM radial forging machine. The
operation. The term, radial forging, appears to be widely used in benefit of these machines is that they introduce uniform work into
Europe to describe the process while both radial and rotary the product and require fewer (if any) reheats. GFM radial forging
forging are commonly used in the United States to describe the of titanium alloys has the benefit of being economical and is a
Process [3]. process that is relatively easy to control, and which yields a
product that has more uniform hot work [4]. This is beneficial
The main advantages of its forming nature are: when developing the desired microstructure in forgings made
x It works the material from all sides (prevents spreading) from the billet. The advanced GFM forging machine has even the
x It requires only small forming forces due to its inherent capability to select (at least in certain steps) the ram speed
incremental characteristics characteristic and therefore it is possible to select a proper strain
rate range.
x It is an open-die process (i.e. the tool set covers a broad
A process route of such a process is indicated in fig. 1b. Figure 2
range of sizes) shows a typical configuration of this GFM radial forging machine.
x It has good controllability (i.e. strain, strain rate and
temperature control) Provided that the GFM radial forging machine has sufficient size
x It is a precise and fast process and forge capability and that no upsetting is required, it is
therefore possible to cancel the open-die forging process step.
There are typically two different targets with radial forging: one is
to create the correct geometry and the other is to execute the
proper forming of the specific material to meet the product
specifications. In the following, we will explore where the GFM
radial forging technology is useful and used in the titanium world.

Titanium and Titanium Alloy Forging

The mechanical properties of titanium alloys are predominantly

determined by the chemical composition as well as the
corresponding microstructure [4].

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 INDUCTION
UNIT

FORGING
DIES

Figure 3. Installation of GFM radial forging machine for Titanium

Figure 1a. Figure 1b. with integrated in-line induction system

Figure 1. (Simplified) process routes for primary forging (a)

typical traditional primary forging process, (b) potential optimized
process. Process Windows for Primary Forging

Process route according to Figure 1b reveals the following Titanium alloys have relatively poor thermal conductivity and
advantages: relatively high flow stresses at all working temperatures.
x No need for the open-die press / capability At high rates of deformation, the thermal conductivity is too low
x higher homogeneity of deformation to allow dissipation of the heat generated during working.
Consequently, titanium alloys may exhibit adiabatic heating
x Notable less number of reheats (and hence reduced
during working. Adiabatic heating can lead to localized flow
hydrogen pick-up). Automatic reheating during forging softening in shear bands. But if the adiabatic heating is well
(in-line reheating) might completely eliminate any controlled it can extend the working time and deformation extent
traditional furnace reheats between reheats.
x Less surface cracks due to shorter process and contact
times (less temperature losses and less chilling) There are material specific constraints and restrictions for which
the forger must account for. The most important ones are shown
x Less length restrictions (better temperature control due in Table 1. There you will find also the consequential forging
to fast GFM process) and integrated in-line induction faults if they are not observed.
system (see figure 3) Process maps have been elaborated [9] showing the combined
restrictions of strain rate and temperature. Together, with
minimum requirements of strain for proper microstructural
evolution, they provide the constraints or guidelines for the forger
regarding the details of forging parameter selection.

Figure 2. Typical GFM radial forging machine layout

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 the symmetry and mechanical periodicity of the process, the
Table 1. Restrictions for the Forger results are more prompt.
Parameter Issue Harmful Reason
Effects The standardized results are condensed to allow an easy
Temperature Too Chill cracking Limited formability comparison to previous simulations. This tool is therefore
low designed for production people to use on a daily basis for the
Temperature Too „burnt“, Microstructure (e.g. coarse development/optimization of the forging routes/pass sequences.
high „Overheated“ grain) The number of real shop trials is distinctly reduced or even
eliminated as a result. This is important as the shop trials are not
Strain Rate Too Too many temperature losses by mainly
only costly but also time consuming.
low reheat cycles chilling and radiation,
for longer bars frequent reheats in air
atmosphere cause hydrogen Whenever a pass sequence is optimized the relevant CNC
and oxygen pick-up program is stored and the process is automatically performed at
Strain Rate Too Local temperature build-up cannot any time with the highest possible repeatability.
high „overheated“, be evenly distributed due to
shear bands, low thermal conductivity A summary result of a typical pass sequence showing
missing temperature, strain, strain rate and a Rodic parameter (for
homogeneity
indications of damage value) averaged over the radius is shown in
Strain Too dead-metal No homogenous material
low zones, not flow, not sufficient worked
fig. 4.
sufficient material
homogenous
material

Strain Too If only locally: If only locally:

high Missing Microstructure may differ
homogeneity
within the
work piece

Parameter Selection on GFM RF-Forging Machines

Based on a certain start and end dimension there are several

available parameters to vary the process. The most important are:
x Selection of tools (geometry)
x Selection of reductions per pass
x Selection of forging direction (one directional or
bidirectional forging)
x Strokes per minute for each pass / stroke skipping mode
x Rotational steps between two strokes

The correct selection of these parameters is not obvious due to the

above mentioned narrow process window.

As the selection is crucial for getting the proper microstructural

properties, the forger needs support to optimize the forging
process to fulfill all the requirements.

FAST FEM Package

Therefore, GFM offers, with its machines, a FAST FEM package.

As a minimum, it provides the forger with a fast evaluation of
temperature, strain rate, strain and certain damage values to check
versus existing process maps restrictions and strain distribution
requests.

With this package a model based on a pass sequence is fully

automatically set-up (automatic pre-processing), calculated and
the results are presented in a standardized form summarizing all
relevant information (automatic post-processing) for the forger.
As the calculation time is reduced to some hours/days by use of

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 Specific GFM Hot Forging Applications
In the following, some products where GFM forging machines are
already employed or might be applicable are reviewed.

Turbine Blades
Titanium blades have had a long and successful application as
aircraft gas turbine blading, particularly in fan blades. For many
decades, GFM forging machines are used for fast and precise
preform forging of these blades [4]. Depending on the selected
forging and heat treatment several different microstructures /
properties are adjustable (e.g. relatively coarse elongated alpha
grain structure, lamellar, equiaxed or bimodal microstructure) [6],
although the focus on this application centers on the geometric
advantages.

To produce the preform, bar material of appropriate length and

diameter is forged on a GFM radial forging machine. The volume
distribution over the length of the preform corresponds to the
respective profile cross-sections of the finished blade. The typical
preforming step is shown in fig 5a. Closed-die forging is then
performed as a final forming step.

Fig. 5a. Fig. 5b.

Figure 5.Radial forging of turbine preforms (a) typical

preforming, (b) advanced preform with twisting

The latest advancement is the possibility to reduce the close-die

forging either to a one-step or eliminate the necessity of closed-
die forging completely (near-net shape forging) if microstructural
targets are met.

This is performed by a more accurate preform geometry forged on

the GFM radial forging machine (see Fig. 5b and Fig. 6). The
forging is performed in such a way, that the preforming is done
traditionally in a first step, but with tools that allow, in the same
heat, in a second operation to forge the flat faces and even twist
Fig. 4 Overview of Temperature, Strain and Strain rate for a pass the blades during the radial forging step, if required.
sequence of Ti-6Al-4V radial forging.

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Figure 6. Hot forged twisted geometry

Titanium and its Alloys for Medical Applications

Biomaterials must fulfill several specific requirements like
biocompatibility, corrosion resistance and a Young’s Modulus
similar to that of bone [7].

Next to stainless steel and CoCr-based alloys CP-titanium and Figure 7. Hot forged airframe strut
titanium alloys, e.g. Ti-6Al-4V are used heavily nowadays due to
their favorable properties. Gas analysis and microstructure also confirmed that the short
period of higher temperature (induction heating, fast forging)
The main task for preforming of hip joints is very similar to the exposure did not harm the material.
turbine blades, although there are some specific issues to manage
in the case of hip joint preforming.

For hip joint preforming, typically the bar blank is heated by Forging Application Example: Forging of PM Titanium Alloys
induction. Due to the low thermal conductivity a well-designed
system is a prerequisite for forging this product without any SINTEF Raufoss Manufacturing AS is developing, for one of
surface faults. To minimize chilling of surface, the tools are their customers, an advanced process for wire making.
preheated. The GFM forging machine is now used worldwide for
this application and has replaced all alternative preforming
processes at most of the leading hip joint suppliers in the last
decade due the following advantages:
x Fully automatically and reliable process
x Fast and robust process
x Minimum set-up time for change-over to other
dimensions
x Easy program generation for new geometry (due to
GFM software for CNC-program creation)
x No need for lubricant/coating
x No need for machining after forging (some customers
even close-die forge afterwards successfully in the same
heat)
Figure 8. Forging of PM Titanium

GFM has previously performed trials to prove its capability to

Structural Aircraft Parts
forge the pre-material in the process route of the required wire.
PM Titanium Material was forged in cold as well as in hot
New aircraft require the most advanced technologies to meet the
condition to sufficient structural integrity for further production.
challenges of sustainability and reduced direct operating costs.
Therefore aircraft designers have continuously improved and
The inhomogeneous material mixture and granularity provides an
promoted the best strength to weight ratio for airframe rods and
interesting challenge in achieving a crack free condition in the
struts.
first forming steps.
GFM has developed a forging process for producing struts from
Ti-6Al-4V. The production sequence is shown in figure 7.
A typical example of such cracks in the transverse direction is
shown the following picture:

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 References

[1] R. Wieser, GFM Radial Schmieden – Technologie und

Weiterentwicklungen, Sommerschule Schmiedetechnik,
Teichalm, Steiermark, 2005, S. 229-243.
[2] H.W.Sizek, Radial Forging – ASTM Handbook 14a, p. 172 ff
[3] J.P. Domblesky, R. Shivpuri, et al, A Review of Radial
Forging Technology including Preform Design for Process
Figure 9. Forging of PM Titanium Optimization, Contractor Report ARCCB-CR-94004, 1994
[4] Christoph Leyens, Manfred Peters, Titanium and Titanium
Based on advantageous stress distribution during GFM Radial
alloys, Fundamentals and Applications
forging after optimization of the specific process, crack-free
[5] G. Lutjering, J.C. Williams, Titanium, 2nd edition
products that allowed further forming steps without difficulties [6] R.I. Jaffee, ed., Titanium Steam Turbine Blading Workshop
could be produced. This is valid for the cold – as well as the hot – Proceedings, Palo Alto, California, 1988
forging condition and both showed acceptable results (see Fig.
[7] J. Breme, E. Eisenbarth, et al., Titanium and its Alloys for
10).
Medical Applications, Universität des Saarlandes
[8] J. V. Scanlan and G. J. G. Chambers, FORGINGS IN
TITANIUM ALLOYS in The Science, Technology and
Application of Titanium, published for the organizing
societies by Pergamon Press, 1968.
[9] T. Seshacharyulu, S.C. Medeiros, et al., Hot Deformation
Mechanisms in ELI Grade Ti-6Al-4V, Scripta Materialia,Vol.
41, pp. 283-288, ISSN 1359-6462

Figure 10. Hot and Cold Forged PM parts

Conclusion

GFM Radial Forging machines provide sufficient and excellent

capabilities to forge all variants of Titanium and Titanium alloys.
In the case of hot forging, it is well suited for primary forging as
well as for near net shape preforms and semi-finished products.
The main advantages for using this kind of machine are:

x Fast and reliable fully automatic process

x High precision of forging of cylindrical or stepped parts
x Automatic reheating during forging (in-line reheating)
capability to reduce/eliminate furnace reheats
x Better control of properties due to higher number of
selectable process parameters
x FAST FEM support for proper selection of forging
strategies and parameters

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