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Metalworking alternatives

Metalworking alternative open-die forging

Forgings can deliver better part strength compared to machined bar, torch cut plate, weldments, fabrications, or castings while saving cost, time, machining labor, and material. Another advantage of forgings is that they are ideal for high quality, safety critical applications, restricted mechanical properties, or special sizes.

Forging Advantages:

What you gain when you select our forgings

  • Stronger parts than those produced by other metalworking processes due to the elimination of porosity, contoured grain flow, and fine grain size
  • Near net shape parts with less material waste and cost for low quantity orders
  • Efficient production methods utilizing in-house tooling
  • Multi-component fabrications can be combined into single piece forgings, resulting in reduced process time
  • Customized shapes and sizes in a wide variety of grades
  • The technical expertise of our sales staff, metallurgists, and forging engineers to help discover ways that reduce costs and improve lead times

Material savings

Forging allows custom sizes and material savings

Our extensive inventory of in-house tooling allows for many custom sizes with quick turnaround for low quantity jobs. Also, for unique applications, we can design specialized tooling.

Problem

When hub shapes are achieved through machining solid bar stock or flame cutting plate, waste is an inescapable part of the process.

Solid bar stock or flame cut plate hub

  • When machining a shape from solid bar or flame cutting plate, all excess material—material paid for—is lost.
  • Machining or flame cutting means costly machine time, lowered tool life and increased freight costs for material.
  • Most importantly, the uni-directional grain flow of both bar and plate increases the likelihood of failure due to fatigue.

Solid bar stock or flame cut plate hub

Solution

Custom forging of hub shapes improves quality, lowers material costs, and offers maximum flexibility.

Custom forging hub

  • Forgings save on both material and freight costs because it requires less starting stock.
  • Our forgings are produced to a nearer net shape, reducing machine time and labor costs.
  • The optimum combination of strength, toughness and fatigue resistance in the hub is achieved by the continuous grain flow which comes through forging.
  • When machining a shape from a solid bar or flame cutting a plate, all byproduct is wasted at the expense of the customer.

Custom forging hub

Hubs 59% material savings

59% material savings

Forged Sizes

  • 20" O.D. X 3" Face
  • Hub one side
  • 9" O.D. X 4-1/2" Projection
  • Weight = 348 lbs.

Plate Size

  • 20" Square X 7-1/2" Thick
  • Weight = 850 lbs.

Hubs 43% material savings

43% material savings

Forged Sizes

  • 18-1/4" O.D. X 3-7/8" Face
  • Hub one side
  • 10-5/8" O.D. X 6-1/8" Projection
  • 3" I.D. Through
  • Weight = 421 lbs.

Bar Size

  • 18-1/4" O.D. X 10" Long
  • Weight = 741 lbs.

Hubs 66% material savings

66% material savings

Forged Sizes

  • 9" O.D. X 1-1/8" Face
  • Hub one side
  • 4" O.D. X 1-3/4" Projection
  • Hub other side
  • 4" O.D. X 3-1/2" Projection
  • Weight = 39 lbs.

Bar Size

  • 9" O.D. X 6-3/8" Long
  • Weight = 115 lbs.

Open die forging and torch cutting allows for a surprisingly large range of sizes and shapes

Torch cutting to near net shape saves on machining times without incurring custom die costs.

Problem

Castings are not always economical and can extend deliveries. Machining from a large block or plate can result in excessive machine times.

  • The need to manufacture dies for specifically shaped castings often result in extended deliveries
  • Castings produce enlarged grain structure, which lowers mechanical properties
  • Excessive costs for small quantity casting runs are incurred due to expensive molds and set-up times
  • When forging to near net is not an option, machining excessive amounts of material from plate is inefficient

Solution

Our forging and torch cutting capabilities allow for intricate jobs to be manufactured economically and with shortened lead times.

  • Our forgings can often be manufactured without the need for custom dies, and our CNC torches can be individually programmed for specialty shapes
  • Forgings produce improved integrity in the finished part for better product reliability
  • Material and labor cost savings through the combination of custom forging near net finished sized with subsequent contour torch cutting.
  • Compared to traditional machining, torch cutting is more efficient, which results in quick turnaround
  • Complete torch cutting capability including pre- and post-heating processes to aid cutting accuracy and relieving stresses for over one hundred different grades of carbon and alloy steels

Torch cut part

Material

  • 1026

Approximate Size

  • 16" Thick X 38" O.D. with a 19" I.D.

Torch cut part

Material

  • 1045

Approximate Size

  • 15" Thick X 20" Wide X 63" Long

Torch cut part

Material

  • 1045

Approximate Size

  • 15" Thick X 20" Wide X 63" Long

Torch cut part

Material

  • 1035

Approximate Size

  • 9" Thick X 26" Wide X 45" Long

Torch cut part

Material

  • 4340

Approximate Size

  • 14" Thick X 30-1/2" Square

Torch cut part

Material

  • 4140

Approximate Size

  • 6" Thick X 53" Wide X 57" Long Cam Shape

Torch cut part

Material

  • 1018

Approximate Size

  • 12" Thick X 18" High X 48" Long

Torch cut part

Material

  • 1021

Approximate Size

  • 11" Thick X 34" O.D. with a hub on one side of 13-1/2" O.D. X 2-1/2" Projection and a 7" I.D.

Torch cut part

Material

  • 4140

Approximate Size

  • 18" Square X 24" Long

Our forging process allows for high-quality hollows

Unlike rolled and welled plate, our hollows are forged seamlessly and utilize in-house tooling to create near net and low cost options.

Problem

Centrifugal castings are not always economical and can extend deliveries.

  • Heavy wall centrifugal castings often fail to meet critical I.D. surface requirements and require welding and re-machining.
  • The need to manufacture dies for specially shaped centrifugals often results in extended deliveries.
  • Excessive costs for small-quantity runs are incurred due to expensive molds and setup times.
  • Centrifugal castings produce enlarged grain structure, which lowers mechanical properties.

Solution

Custom hollow forgings offer consistently high quality, often at lower costs and with quicker turnaround times.

  • Hollow forgings are uniformly forged with guaranteed soundness regardless of section size.
  • Our extensive in-house tooling enables us to forge a large variety of hollows without added costs or extended lead times.
  • Setup time is nonexistent for hollow forgings, keeping costs and lead time to a minimum whether the quantity is one or one hundred.
  • Our forging process produces a seamless cross section and continuous grain flow which yields the optimum combination of fatigue strength and toughness.
  • The hollow forging process offers a greater variety of O.D. as well as I.D. configurations thus reducing machining time and cost.
  • Using our custom engineered, in-house tooling, we are able to provide thick walled hollows with multiple steps on both the O.D. and I.D.

Forged hollow

Forging Process

Rejection - 0%

Continuous grain flow shown on a stepped O.D. and I.D. in the as-forged condition.

Cast hollow

Centrifugal Casting Process

Rejection - 10%

The same part shown with columnar grain flow in the as-cast condition.

Note extra stock on the O.D. and I.D. required for centrifugal casting vs. forging

Forged hollow size capabilities

Size capabilities

Simple hollow

  • Max. O.D. = 70"
  • Min. Wall = 2" thick
  • Max. Length = 360"
  • Max. Wt. = 70,000 lbs.

50% forged hollow material savings

50% material savings

Forged Size

  • 26" O.D. X 5" Long, Step
  • 21" O.D. X 20" Long, Step
  • 17" O.D. X 20" Long
  • 11" I.D. Through
  • Weight = 2,789 lbs.

Centrifugal Cast Size

  • 26" O.D. X 45" Long
  • 11" I.D. Through
  • Weight = 5,557 lbs.

58% forged hollow material savings

58% material savings

Forged Size

  • 32-7/8" O.D. X 5-7/8" Long, Step
  • 18-1/2" O.D. X 21-1/4" Long, Step
  • 32-7/8" O.D. X 5-1/8" Long
  • 15-3/4" I.D. Through
  • Weight = 2,483 lbs.

Centrifugal Cast Size

  • 32-7/8" O.D. X 32-1/4" Long
  • 15-3/4" I.D. Through
  • Weight = 5,975 lbs.

36% forged hollow material savings

35% material savings

Forged Size

  • 15" O.D. X 7" Long, Step
  • 25" O.D. X 15" Long, Step
  • 15" O.D. X 7" Long
  • 9" I.D. Through
  • Weight = 2,264 lbs.

Centrifugal Cast Size

  • 25" O.D. X 29" Long
  • 9" I.D. Through
  • Weight = 3,510 lbs.

Forged rings are able to be individually customized for near net shape

In material cost, versatility and quality, forged ring solutions deliver superior outcomes compared to flame cutting rings from plate.

Problem

Flame cutting a ring from plate is not always viable when meeting material requirements, or economical.

Flame cut ring

  • Material costs are increased due to removal of excess corner stock and center slug.
  • As desired thickness of the ring increases, availability of plate sizes and grades drastically decreases.
  • Uni-directional grain flow of plate increases susceptibility of ring to fatigue failure.

Flame cut ring

Solution

A custom-forged ring allows greater versatility and improved quality while reducing material cost.

Forged ring

  • The forging process moves and shapes material to ordered ring size with minimal material waste.
  • Required ring thickness has no effect on the virtually limitless combinations of sizes and grades available.
  • Contoured grain flow within forged ring yields optimum combination of strength, toughness and fatigue resistance.
  • The porosity and laminations sometimes encountered in plate is eliminated with a custom-forged ring.

Forged ring

43% ring material savings

43% material savings

Material

  • 4340

Finished Size


  • 46-5/8" O.D. X 26-1/4" I.D. X 
6-5/8" Face

Material Needed to Produce


  • Forging = 2,925 lbs.
  • Plate = 5,090 lbs.

43% ring material savings

43% material savings

Material

  • 1021

Finished Size


  • 22-5/8" O.D. X 17" I.D. X 9" Face

Material Needed to Produce


  • Forging = 700 lbs.
  • Plate = 1,580 lbs.

Size variety ring

Size variety

Material

  • 1045

Finished Size

  • 52-1/4" O.D. X 19-3/4" I.D. X 31" Face

Material Needed to Produce


  • Forging = 19,500 lbs.
  • Plate = Unavailable at this thickness

Our forged stepped spindles allow endless flexibility in size and variation

Reduce material waste, machine times, and freight costs with forged stepdown solutions instead of machining solid bars.

Problem

Machining a solid bar to form a step-down causes wasteful use of material, labor and time.

Machined spindle

  • When machining the step-down, all excess material, as shown here, is lost.
  • Machining time, tool life and freight costs are excessive.
  • Grain flow within the bar is exposed when machined, thus making the material more susceptible to fatigue failure.

Machined spindle

Solution

Custom-forging the bar to form a step-down lowers the cost for a value-added part.

Forged spindle

  • Forging requires less starting material than a straight round bar machined to shape.
  • Less machining saves money, time and tool life while producing a closer-to-finish shape.
  • Freight and handling costs are lowered because a forged stepdown weighs less than a bar.
  • Contoured grain flow within a forged stepdown yields greater impact and directional strength.

Forged spindle

64% forged spindle material savings

64% material savings

Forged Sizes

  • 18-1/4" O.D. X 16-1/2" Long, Step
  • 11-1/4" O.D. X 8" Long, Step
  • 6-3/4" O.D. X 48" Long
  • Weight = 1,935 lbs.

Bar Size

  • 18-1/4" O.D. X 72-1/2" Long
  • Weight = 5,375 lbs.

49% forged spindle material savings

48% material savings

Forged Sizes

  • 4" O.D. X 19-13/16" Long
  • 6-1/2" O.D. X 9-3/8" Long, Step
  • 4" O.D. X 13-1/16" Long, Step
  • Weight = 207 lbs.

Bar Size

  • 6-1/2" O.D. X 42-1/4" Long
  • Weight = 367 lbs.

59% forged spindle material savings

59% material savings

Forged Sizes

  • 7-1/8" O.D. X 40" Long, Step
  • 10-1/2" O.D. X 18" Long, Step
  • 14" O.D. X 12" Long, Step
  • 10-1/2" O.D. X 18" Long, Step
  • 7-1/8" O.D. X 40" Long
  • Weight = 2,310 lbs.

Bar Size

  • 14" O.D. X 128" Long
  • Weight = 5,582 lbs.