M. E. Epler, A. Patel, G. Maurer, Carpenter Technologies, Reading, PA; V. Mendoza, Carpenter Technology Corporation, Reading, PA

Summary: Commercially available computation modeling packages present great opportunities for advancement in alloy and process development programs. These packages allow for timely and cost effective analysis of a wide range of processing and metallurgical variables when performing research and development. Modeling can be used to solve problems in current products and processes or be applied to the design and implementation phases of new products and processes. This presentation will discuss some of the uses of modeling in aerospace alloy production and R&D environments where a great number of different processing routes exist. Solidification modeling may be used to determine optimum casting parameters to increase yields and improve cleanliness during primary melt processing. VAR and ESR modeling packages can be used to minimize segregation during secondary melting. Thermo-mechanical modeling may be used to optimize heating times and cooling rates and to develop deformation strategies to ensure uniform macrostructures and to avoid centerline and surface cracking. All of the process models help the process engineer design processes within the design capability of the equipment. The long tedious trial-and-error method to process scale-up is becoming obsolete. Modeling can give insight into material behavior during processing that may not be available otherwise, especially in full-scale, large-section size products. This ability shortens the time for alloy development and scale-up from small laboratory-based heats to full-scale production without many costly trials. Some current limitations of modeling software will be discussed and speculation on opportunities for advancement will be made.