1. Aviation Forging and Casting Assistance Team
Casting & Forging
Aviation Forging and Casting Assistance Team
May 15-16, 2018
FOR OFFICIAL USE ONLY

2. Casting & Forging
Aviation Forging and Casting Assistance Team (AFCAT) Jeannie Kirby AFCAT Program Manager Walker George Forgings Application Engineer Keith Sturgill Castings Application Engineer
FOR OFFICIAL USE ONLY

3. Mission Relevance Proactive Reviews
Decreased lead-time and reduction of unfilled orders
Reduction in cancelled contracts
Provide sourcing solutions for challenges presented by military aviation requirements
Assistance to contractors requesting information on tooling for Cast or Forged items
FOR OFFICIAL USE ONLY

4. Sustainment Horizon “The Perfect Storm”
Challenges for procurement:
Small quantity orders
Long lead times
Infrequent buys
Labor intensive RFQ System
Non-existent/missing tooling
Objective:
A more innovative approach
Responsive to industry concerns
Utilization of industry expertise
Sharing of knowledge
FOR OFFICIAL USE ONLY

5. Weapons Systems Sustainment
Castings and forgings represent about 4% of DLA solicitations but 15-20% of backorders over 180 days
Forgings/castings is hindered by
Lost or hard to locate tooling
Fragmented supply chains
Inadequate procurement data
Diminishing supply base
Hog it out?
FOR OFFICIAL USE ONLY

6. Source Approval Requests (SAR)
AFCAT assistance with Casting and Forging SAR submissions
Reverse Engineering opportunities
RPPOB
Proprietary items
Recent example
B-52 Drag Link
Problem
Organic manufacture unable to produce parts
Parts are CSI and required to be made from a forging
Part has a demand of 72 ea per year, no stock on hand
Need to find a vendor to make part
Details
NSN
Drag Link, Landing Gear
Weapon System B 52
Solution
AFCAT/FORGE-IT contacted a forge shop to see if they would be interested in submitting a SAR on this NSN.
FORGE-IT team member meet with Forger and parting machine shop on December 07, 2015 and went over the SAR submittal process.
SAR was sent in to VE in January 2016, reviewed by VE engineer and sent to ESA on February 02, 2016.
Reply from USAF ESA on February 24, 2016 (SAR approved)
Contract was awarded to Forger/Machine Shop August 22, 2016
VE STARS project CF, drag link was approved on Aug. 31, Total savings on this first buy was $950, This project should generate a huge amount of follow on savings for the next 6 ea per year.
FOR OFFICIAL USE ONLY

7. Casting/Forging Clauses
“A metal casting process was identified as a means to manufacture this item. Tooling is required to produce a casting. For sourcing, tooling, materials or other information, please contact the appropriate assistance team: (Aviation, C&E Supply Chains) ; (Land & Maritime Supply Chains)
“A forging process was identified as a means to manufacture this item. Tooling is required to produce a forging. For sourcing, tooling, materials or other information, please contact the appropriate assistance team: (Aviation, C&E Supply Chains) ;(Land & Maritime Supply Chains)
FOR OFFICIAL USE ONLY

8. Future Initiatives AFCAT review of PR lists
Consolidated Web Portal R&D
Magnesium Casting Source Development
Expanding the use of Rapid Prototyping
Boeing Rights Guard
Item transfers to DLA
Long-term contracting for grouping of castings and forgings
FOR OFFICIAL USE ONLY

9. The American Metalcasting Consortium Engineering Team
11/9/2018
Primary experience with steel, titanium, aluminum, magnesium, zinc, brass
Metalcasting consultants totaling 155+ years of casting experience
Casting related machining, post-processing, rapid prototyping, and tooling expertise
Leveraging real world experiences and new technology tools
Linking government and industry to support successful procurements
Jack Church Minneapolis, MN
Dick Farrara Albany, NY
Keith Sturgill Richmond, VA
Gary Burrow Billings, MT
Dave Poweleit Chicago, IL
Jenny Swygert Charleston, SC
Mike Gwyn Charleston, SC
FOR OFFICIAL USE ONLY

10. The Forging Defense Manufacturing Consortium Team
Walker George
Richmond, VA
Prabir Chaudhury
Phoenix, AZ
Dekland Barnum
Charleston, SC
Chris Bergner
Charleston, SC
FOR OFFICIAL USE ONLY

11. The Aviation Forging and Casting Assistance Team
Keith Sturgil
Richmond, VA
Walker George
Richmond, VA
Kyle Hedrick
Richmond, VA
Jeannie Kirby
Richmond, VA
Dekland Barnum
Charleston, SC
FOR OFFICIAL USE ONLY

12. Where to get help AFCAT Assistance Requests:or
Assistance in location of Forging Dies
National Forging Tooling Database (NFTD) available through IHS Haystack Gold
Assistance in location Casting Patterns
Available through the Non Ferrous Foundry Society (NFFS)
American Metalcasting Consortium (AMC)
Forging Defense Manufacturing Consortium (FDMC)
FOR OFFICIAL USE ONLY

13. Questions/Concerns
Questions
FOR OFFICIAL USE ONLY

14. DEFENSE LOGISTICS AGENCY
AMERICA’S COMBAT LOGISTICS SUPPORT AGENCY
WARFIGHTER SUPPORT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT
FOR OFFICIAL USE ONLY