Date of Award

2026

Document Type

Open Access Master's Thesis

Degree Name

Master of Science in Materials Science and Engineering (MS)

Administrative Home Department

Department of Materials Science and Engineering

Advisor 1

Joshua Mueller

Committee Member 1

Walter Milligan

Committee Member 2

Pat Nowak

Abstract

Heat checking, characterized by biaxial networks of surface cracks induced by thermomechanical cycling, can cause premature failure of open-die forge tooling. To facilitate the evaluation of heat checking resistance of die steels, a simulation‑informed out-of-phase thermomechanical fatigue (OP-TMF) testing methodology was developed using 4330V steel as a baseline material. Temperature‑dependent material properties and flow stress data were collected and compiled into a material data file for use with finite element analysis software. Forging and cooling scenarios were simulated across a range of die preheat temperatures. Temperature and in-plane strain histories extracted from the die surface provided a foundation for laboratory OP-TMF profile construction. Iso-strain OP-TMF experiments were performed in a Gleeble 3500 thermomechanical simulator. Predicted stress evolution was successfully reproduced. Peak tensile stress data from load‑displacement hysteresis loops were used to construct stress-cycle curves, providing a quantitative metric for comparison of heat checking resistance. This work establishes a high-fidelity framework for rapid assessment of heat checking resistance in open-die forge tooling materials, enabling improved die steel selection and process optimization.

Download

Included in

Metallurgy Commons

Share

COinS