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When it comes to component reduction, less is more.

It is often possible to reduce cost and production time, while increasing quality, by keeping the part's components to a minimum. By evaluating finished prints or models, Scot Forge can eliminate unnecessary steps and expenses by producing a single component rather than two or three fabricated together. Below are a few examples.

Product/application

Heat exchanger body

Material

90/10 Copper Nickel

Navel

Previous processing problems

Part originally consisted of three components: one rolled and welded plate and two forged rings welded to the ends.

  • The two different metalworking processes made the welding difficult with inconsistent results.
  • Inclusions were present in the plate, requiring extensive weld repair and reinspection.
  • Weld areas required expensive X-ray testing.
Navel

Forging as the solution

Today the part is made as a single forged piece with integral flanges.

  • Consistent quality is assured throughout the part, eliminating the instances of inclusions, making welding unnecessary.
  • Without welding, X-ray testing is not needed.

Product/application

Cylinder rod for bucket

Material

Low-Alloy Steel

Shovel

Previous processing problems

Previously the part was made from a cast head welded to a hot rolled bar.

  • Casting proved too weak for the application, resulting in shortened product life.
  • The need for welding lengthened process times.
  • In the field, excessive loads on the cast head caused part failures and required subsequent repairs.
Shovel

Forging as the solution

Today the part is made as a one-piece forging.

  • Forging allowed the head and shaft to be produced as one part.
  • The strength and structural integrity of the forged material met demanding application requirements.
  • The elimination of welding has shortened part production process time.
  • The forged head is able to withstand excessive loads without failure.

Product/application

Mixer shaft

Material

Stainless Steel

Paper

Previous processing problems

The former part was a rolled bar welded to a forged blank.

  • Heating required during the welding process changed the hardness and tensile properties in the weld zone, making it necessary to re-heat treat the part.
  • Cracking was occurring in the weld layer, rework was needed, and there were many failures in the field.
Paper

Forging as the solution

Today the part is made as a one-piece forging.

  • No welding or heating is required, improving properties and eliminating non-value-added steps.
  • Part strength has improved due to one-piece construction and continuous grain flow, resulting in less rework, fewer rejections and increased part life.