New processes that include a number of novel techniques such as advanced roll forming methods, equal-channel angular extrusion, and incremental forging.
Processes for new materials such as structural-intermetallic alloys and discontinuously-reinforced metal-matrix composites (MMCs) including dramatic approaches for the bulk forming of aluminide-based intermetallic materials and the utilization of commercial scale bulk forming for aluminum-alloy MMCs and, to a lesser extent, titanium-alloy MMCs.
Improved microstructural control via specialized thermomechanical processing (TMP) of ferrous and nonferrous alloys with recent advances that include: TMP of ferrous alloys to produce carbide-free steels with bainitic microstructures and TMP of nickel-base superalloys to improve damage tolerance or creep resistance in service by techniques that produce a uniform intermediate grain size (ASTM ∼6) or a graded microstructure.
Advanced tools for predicting microstructure evolution based on phenomenological models (predicting, for example, the evolution of recrystallized volume fraction and recrystallized grain size that evolve during hot deformation) and mechanistic models that incorporate deterministic and statistical aspects to varying degrees and seek to quantify the specific mechanism underlying microstructure changes.
Advanced tools for predicting texture evolution based on models for the prediction of either deformation textures or recrystallization/transformation textures.
Advanced modeling and optimization techniques using powerful and inexpensive computer hardware and software that have resulted in a revolution in the design of bulk-forming processes.