Isothermal Forging of Ti-6Al-4V Alloy as an Improved Process for Fabricating Weapon Components

A program to evaluate the isothermal forging of titanium alloys, e.g. , Ti-6Al-4V, as an improved manufacturing process for the production of light weight, high strength weapon components has been conducted. The program was performed in two phases. The first phase consisted of the isothermal forging of a simulated weapon component having thin high ribs, a large volume projection, and a uniformly thin web. This effort established optimum starting material properties, preform design, lubrication practice, tooling design and forging conditions. The important aspects of lubrication and preform design were explored in detail. The results of the first phase work were incorporated into a process specification which was used as a basis for the second phase effort. The second phase consisted of the manufacture of a demonstration weapon component, the M85 Macine Gun Cover, by isothermal forging.