Thermally Enhanced Material Processing at Elevated Rates
Temper specializes in delivering solutions to customers. We (the team) work closely with our customers to understand what they need, and then focus on delivering solutions for those needs.
Team focused projects
TiPAD - Titanium Puck and Densification (PAD) / Technologies for Affordable Mass Production of Automotive and Aerospace Components
The titanium puck and densification (PAD) program addresses the problem of mass producing lightweight, high temperature engine components for automotive applications. The solution is to create a contaminant-free, self-skinned puck from inexpensive powdered titanium and rapidly densify it into a solid near-net shape component that is over 99.9% porosity free using mass production techniques.
The Phase I program demonstrated the ability to densify powdered titanium in a mold cavity to create near-net shapes using a powder pack. The powder pack is essentially a can that is filled with titanium powder and purged to remove gaseous contaminants. The powder pack is then placed in a mold with a complex geometry and processed into a solid component using thermal cycling to densify the material.
The Phase II program continues developing the process by demonstrating the densification process using mass production concepts. Work is planned to developed a skinned puck made from pre-formed powder and skinned to seal out contaminants. This allows for the staging of the components in a production-line manufacturing system. Additionally, further research is done to reduce densification process cycle time to a matter of minutes. The puck and densification process are two separate technologies but work together to enable mass production of low cost, high quality titanium components for automotive, aerospace, and healthcare industries.
Potential applications for the technology include the lightweighting of automotive engine components such as connecting rods and valve systems, near-net shape aerospace components such as turbine blades and landing gear linkages, and low cost medical components like knee and hip replacements.
Phase I con rod - no porosity
Mag Forming - Harnessing Magnetoplasticity for Low Temperature Forming of Thick Gage Armored Steels
The goal of the Phase II research is to demonstrate the forming of armored steel plate using magnetoplasticity. This technology, called Mag Forming, is based on the phase I results that will demonstrate a new forming technology, by creating samples using a V form tool and quantify the technology’s capability to allow complex die forming of armored steel components for applications ranging from underbelly protection to light truck door skins. The research will design and build the tools required to create the V forms from RHA and HHA with a bend radius less than or equal to three times the material thickness and generate the data required to produce a forming limit diagram all while maintaining 95% of the preformed RHA and HHA properties.
The research will demonstrate a new forming technology, called Mag Forming, that will enable complex die forming of armored steel components for applications ranging from underbelly protection to light truck door skins. Additionally, the process creates conditions that enables greater formability of rolled homogenous armor (RHA) and high hard (Hi-hard) armor for material thicknesses up to 50 mm while maintaining 95% of the pre-processed material properties.
Induction Consolidation/Molding of Thermoplastic Composites Using Smart Susceptors - DOE GO 18135
The objective of this project was to explore and define the technical and economic viability of induction consolidation of the thermoplastic composites to fabricate a wide spectrum of components making up a number of products in an energy efficient manner. The markets investigated in detail were aerospace, automotive and wind turbines.
The main technical objectives of the project.
Process characterization – Predictive modeling, simulation and system scalability.
Process validation – Prototyping of full size production tooling.
Process Scalability – Develop designs (tooling/equip.) for mass volume/large size.
Energy Efficiency – Quantify the existing energy used to the new process.
Economic objectives of the project
Create process cost baseline of tooling, equipment and processing.
Create part application database, focused on product applications.
Hot Metal Gas Forming - NIST-ATP
Lead by William (Bill) Dykstra, the process called Hot Metal Gas Forming is an outgrowth of the super-plastic forming process (as used in the aerospace industry for forming low volume aluminum and titanium structures) and the hot blow forming process (as used in the plastics industry for high-volume commercial products - I.E. beverage containers)
The objectives of the program were to
Verify Feasibility of the process (simple laboratory tooling)
Build a prototype mass production system using tooling and equipment
To prove out low temperature enhanced plasticity techniques at high strain rates
Near Zero Stamping NIST-ATP program
Lead by Earnest O. Vahala, the Near Zero Stamping program was focused on increasing the precision of stamped parts to make a substantial contribution toward further improving the quality of the average U.S. automobile. Working with the Big 3 automakers and four research organizations the 23 member companies of the Auto Body Consortium (ABC) pursued design and processing advances to achieve unprecedented levels of accuracy, efficiency, and agility in stamping operations. Goals included achieving dimensional tolerances of better than 1 millimeter--compared with the previous industry best of a bit less than 2 mm--and a 30 percent reduction in the time it takes to design, test, and produce new stamping dies and associated tooling.
Intelligent Resistance Welding - NIST ATP Program
Lead by William Faitel, the Intelligent Resistance welding program was in cooperation with the "Big 3" U.S. auto makers and five research organizations, undertook a effort to develop the knowledge base and then the underlying technology needed to characterize and control all the factors that affect the quality of welds. They will developed sensor-based process monitoring and control systems that keep key process variables within the ranges required to achieve high-quality welds. A key element was the development of neural network models that mimic the behavior of the welding process.