Advanced Metalworking Solutions for
Naval Systems that Go in Harm's Way

Enhanced Processing for High Strength Steel Castings and Forgings for Naval Components


Reduce naval ship fabrication costs by eliminating costly rework and possible in-service failures due to hydrogen-assisted cracking (HAC) in high-strength steel castings and by eliminating preheat of high-strength steel castings and forgings during welding.

Technical Approach

  • Determine optimum thermal soaking treatment to mitigate HAC in HY-80 and HY-100 castings
  • Develop or improve existing analytical or numerical tools to predict residual stresses and hydrogen distribution in castings
  • Confirm properties of high-strength steel replacement(s) for HY-80 and HY-100 castings and forgings
  • Produce full-scale casting and forging to demonstrate ability to achieve properties in actual components


Mitigation of HAC will reduce costly rework and possible in-service failures. Reduced preheat cost should save about $1.6 million per year. More easily processed alloys should reduce production risk and broaden supplier base; a 5-percent acquisition savings ($110,000 per year) is expected due to increased competition.


NAVSEA will certify the alternate casting and forging compositions for use in ship construction, overhaul or repair. The NCEMT will provide technical input for certification including information on processing, mechanical properties and weldability.