Understanding your choice of forged discs options
As a buyer, understanding your choice of forged discs options can be a daunting task. With a plethora of options available in the market, it can be overwhelming to know which option to choose that best suits your needs. In this article, we’ll provide you with comprehensive details on forged discs to help you make an informed decision when purchasing.
Understanding your choice of forged discs options is crucial in selecting the best option that suits your needs. Consider factors such as material type, size and shape, manufacturing process, and cost when making your choice. Choose forged discs for their exceptional strength, reduced risk of failure, cost-effectiveness, and customization options.
What are forged discs?
Forged discs are discs, wheels, covers, and other pie-like shapes of forgings; the one-way forging ratio is large, and the metal flow line is more parallel to the upper and lower planes.
Types of forged discs
Several types of forged discs are designed for specific applications and industries. The most common types include:
Flat Forged Discs
Their flat surfaces and uniform thickness characterize flat forged discs. They are used in applications where the disc needs to provide a consistent, stable base for other components. Common applications for flat forged discs include flanges, valve bodies, and heavy machinery components.
Contoured Forged Discs
Contoured forged discs have a non-uniform thickness and are shaped to meet specific design requirements. This type of forged disc is commonly used in aerospace and automotive applications, where the disc needs to conform to the contours of the surrounding components for improved aerodynamics and weight reduction.
Stepped Forged Discs
Stepped forged discs feature multiple thickness levels across the disc’s diameter, increasing strength and rigidity in specific areas. These discs are often used in heavy machinery and high-pressure applications, where the disc must withstand significant forces and stresses.
Hollow Forged Discs
Hollow forged discs have a central cavity, reducing the overall weight of the component while maintaining its strength and rigidity. Hollow forged discs are commonly used in aerospace and automotive applications, where weight reduction is crucial for improved performance and fuel efficiency.
Materials Used in Forged Discs
Forged discs can be made from various materials, each with unique properties suited for specific applications. Some common materials include:
| Titanium forged discs | ASTM B381 / ASME SB381, Titanium Gr. 1, Titanium Gr. 2, Titanium Gr. 4, Titanium Gr. 5, Titanium Gr. 7, ASTM R50250/GR.1| R50400/GR.2 | R50550/GR.3 | R50700/GR.4 | GR.6 |R52400/GR.7 | R53400/GR.12 | R56320/GR.9 |R56400/GR.5 |
| Copper forged discs | T1, T2, C10100, C10200, C10300, C10400, C10500, C10700, C10800, C10910,C10920, TP1, TP2, C10930, C11000, C11300, C11400, C11500, C11600, C12000,C12200, C12300, TU1, TU2, C12500, C14200, C14420, C14500, C14510, C14520, C14530, C17200, C19200, C21000, C23000, C26000, C27000, C27400, C28000, C33000, C33200, C37000, C44300, C44400, C44500, C60800, C63020, C68700, C70400, C70600, C70620, C71000, C71500, C71520, C71640, etc |
| Copper Nickel forged discs | ASTM / ASME SB 61 / 62 / 151 / 152, Copper Nickel 90/10 (C70600 ), Cupro Nickel 70/30 (C71500), UNS C71640 |
| Carbon Steel forged discs | ASTM/ASME A/SA105 A/SA105N & A/SA216-WCB, DIN 1.0402, DIN 1.0460, DIN 1.0619, Die Steel, ASTM A105 / ASME SA105, A105N, ASTM A350 LF2 / ASME SA350, High Yield CS ASTM A694 / A694 (F52 F56 F60 F65 F70 F80) |
| Stainless Steel forged discs | ASTM/ASME A/SA182 F304, F304L, F316, F316L, ASTM/ASME A/SA351 CF8, CF3, CF8M, CF3M, DIN 1.4301, DIN 1.4306, DIN 1.4401, DIN 1.4404, DIN 1.4308, DIN 1.4408, DIN 1.4306, DIN 1.4409 |
| Alloy Steel forged discs | ASTM A182 / ASME SA182 F5, F9, F11, F12, F22, F91 |
| Hastelloy forged discs | ASTM B564 / ASME SB564, Hastelloy C276 (UNS N10276), C22 (UNS N06022), C4, C2000, B2, B3, X |
| Brass forged discs | 3602 / 2604 / H59 / H62 / etc. |
| Inconel forged discs | ASTM B564 / ASME SB564, Inconel 600, 601, 625, 718, 783, 690, x750 |
| Monel forged discs | ASTM B564 / ASME SB564, Monel 400 (UNS No. N04400), Monel 500 (UNS No. N05500) |
| Duplex forged discs | S31803 / S32205 A182 Gr F51 / F52 / F53 / F54 / F55 / F57 / F59 / F60 / F61 |
| Super Duplex forged discs | S32750 / S32760 A182 Gr F51 / F52 / F53 / F54 / F55 / F57 / F59 / F60 / F61 |
| Alloy 20 forged discs | ASTM B462 / ASME SB462, Carpenter 20 Alloy, Alloy 20Cb-3 |
| Aluminium forged discs | 5052 /6061/ 6063 / 2017 / 7075 / etc. |
| Nickel forged discs | ASTM B564 / ASME SB564, Nickel 200, Nickel 201, Nickel 205, Nickel 205LC |
| Nimonic forged discs | Nimonic 75, Nimonic 80A, Nimonic 90 |
| Other forged discsmaterial | Tin bronze, Alumunum bronze, Lead bronze |
| Incoloy forged discs | ASTM B564 / ASME SB564, Incoloy 800, 800H, 800HT (UNS N08800), 825 (UNS N08825), 925 |
| 254 Smo forged discs | ASTM A182 / ASME SA182, SMO 254/6Mo, UNS S31254, DIN 1.4547 |
Dimensions of Forged Discs
The dimensions of forged discs play a significant role in determining their overall performance, functionality, and compatibility with specific applications. Proper dimensions ensure the disc fits perfectly within its intended environment, allowing for seamless operation and optimal performance.
Diameter: One of the most critical dimensions of a forged disc is its diameter. Depending on the application, the diameter can range from small sizes, such as 2 inches, to large sizes, such as 144 inches.
Thickness: The disc’s thickness is another vital dimension, directly impacting its strength, rigidity, and overall durability. Thicker discs are better suited for heavy-duty applications, while thinner discs are ideal for lightweight applications.
The Forging Process of forged discs
Forged Discs are solid forgings, typical forgings forged on hydraulic presses that require direct forging and forming with high-quality large steel ingots. The forging process of large Forged Discs is traditionally one of the most difficult forging technologies to master in large forgings because the ingots have their inherent defects, such as segregation, inclusions, looseness, coarse columnar crystals, etc.; with the improvement of metallurgical quality, these defects can be reduced, but not eliminated. This results in the actual production of ultrasonic flaw detection once the pass rate is below 50%, high scrap rate, high production costs, and large losses for enterprises. The traditional cake forging technology is confined to the inherent upsetting – drawing length – upsetting forming process concept based on continuous process improvement. However, the pass rate of forgings has improved, in general, because there is no breakthrough in the original process, subject to the Traditional process’s inherent defects, too many factors affecting the process parameters, difficulty to master, forging quality fluctuations, and did not fundamentally solve the forging process problems of this type of forgings. Forged Discs are conventionally forged into many dense defects within a certain distance from the center; the defects are transverse cracks, with no white spots, caused by intense shear deformation in the metal weakness, for inclusions type cracks. Forging process, due to the traditional Forged Discs final forming process is upsetting forming, general upsetting is relatively large, especially in the heart of the deformation is intense, the strain state for the longitudinal compression, two-way stretching, the formation of streamlined inclusions formed by the former pulling length of compression deformation and the formation of lamellar inclusions, increasing the area of inclusions and inevitably become lamellar, that is, the subsequent upsetting deformation destroyed the former pulling length of the inclusions on the Inclusion refinement and dispersion effect, reflected in the ultrasonic flaw detection results in the heart of a certain area showing large dense defects, failing ultrasonic flaw detection.
Forged Discs Solutions
We offer a large Forged Discs forging process that does not present large dense defects in the core area of the forged part and improves the quality of the part.
The technical solution used to achieve the above purpose is a large Forged Discs forging process, characterized in that the forging process is carried out in the following steps in particular:
- Step 1: Heating the ingot to be forged according to the material of the ingot and holding it so that the temperature of the heart of the ingot is the same as the external temperature and the ingot is uniformly heated through;
- Step 2: The ingot is drawn to length using the existing forging method with an anvil width ratio of 0.8-0.9; each press-down rate is at least 20%, and the ingot is drawn to length in one pass; then the square stage is entered: the WHF forging method, the SUF forging method or the TER forging method is used, and the forging is carried out using the staggered anvil drawing process: the first plane is first forged on the ingot along the length of the ingot, and then this first plane is placed on the anvil, forging a second plane parallel to the first plane on the ingot, then placing the ingot on the anvil so that the two planes already forged are perpendicular to the anvil surface, forging a third plane perpendicular to the first plane, after which the third plane is placed on the anvil, and a fourth plane is forged;
- Step 3: Forging the flat square in the height direction using the wide anvil forging method with an anvil width ratio of 0.8-0.9 to form the billet;
- Step 4: Calculating the undercut dimensions based on the weight of the forging and making the length-to-billet width ratio of the billet obtained by undercutting ≤ 1.5;
- Step 5: Forging the billet into a square according to the existing forging method, then inverting the octagon, and finally inverting the round to obtain a semi-finished product;
- Step 6: Forging and forming the semi-finished products according to the existing forging method to obtain large Forged Discs.
The forging process is completely different from the existing Forged Discs forging process route. Various special forging methods are used to compact and forge through the billet during the drawing length process. The previous forging organization and flow lines are retained in the subsequent upsetting forming without destroying the flow lines, making full use of the flow lines formed by the previous drawing length, which fundamentally solves the technical difficulties of tube plate forging. The process route is simple, the technology is reliable, the ultrasonic flaw detection rate of forgings is close to 100%, and the mechanical properties are excellent, which can fully meet product performance requirements.
Application of Forged Discs
Forged discs’ unique properties and advantages make them ideal for various applications across different industries:
- 1. Automotive Industry: Forged discs are commonly used in the automotive industry to produce essential components such as connecting rods, transmission gears, and axle shafts. These components require high strength and durability to withstand harsh operating conditions and ensure vehicle reliability and performance.
- 2. Aerospace Industry: The aerospace industry relies on forged discs for manufacturing critical components such as landing gear, engine parts, and structural components. The superior strength-to-weight ratio, corrosion resistance, and durability offered by forged discs make them ideal for aerospace applications, where safety and performance are crucial.
- 3. Oil and Gas Industry: Forged discs are employed in the oil and gas industry for manufacturing valves, fittings, flanges, and other components exposed to high pressure and temperature conditions. The improved mechanical properties and resistance to fatigue offered by forged discs make them suitable for these demanding applications.
- 4. Power Generation Industry: In power generation, forged discs manufacture turbine components, generator parts, and other high-stress components. These components require high strength, resistance to wear, and the ability to withstand high temperatures and pressures, making forged discs an ideal choice.
- 5. Shipbuilding and Marine Industry: The shipbuilding and marine industry benefit from the corrosion resistance, strength, and durability of forged discs. They are used to manufacture propeller shafts, rudders, and other structural components that need to withstand the corrosive marine environment.
- 6. Heavy Machinery and Equipment: Forged discs produce gears, shafts, and other components. These components require high strength and durability to withstand extreme operating conditions and minimize wear and tear.
- 7. Construction Industry: The construction industry uses forged discs to manufacture anchors, fasteners, and other components that provide structural support and stability. The increased strength and durability of forged discs make them suitable for these applications.
How to purchase the correct forged discs?
To purchase the correct forged discs, there are several factors to take into account:
Material of Forged Discs
Selecting the right material is crucial for your project. Common materials for forged discs include carbon steel, stainless steel, alloy steel, aluminum, copper, and titanium. Each material has its advantages and disadvantages, so choosing the one that best suits your application is essential.
Size and Shape of Forged Discs
The size and shape of the forged disc should match the requirements of your project. Consider the dimensions, such as diameter, or thickness. Custom sizes and shapes can also be requested from the supplier.
Tolerance and Straightness of Forged Discs
Tolerance refers to the allowable variation in dimensions, while straightness is the degree to which the disc is free of bends or twists. Higher tolerance and straightness standards ensure better quality and performance of the forged discs. Make sure to specify your desired tolerance and straightness requirements when purchasing.
Surface Finish of Forged Discs
The surface finish of a forged disc can affect its performance, corrosion resistance, and appearance. The choice of surface finish depends on your application and aesthetic preferences.
Heat Treatment of Forged Discs
Heat treatment can significantly alter the mechanical properties of the forged discs, such as hardness, strength, and ductility. Depending on your application, you may require specific heat treatment processes like annealing, normalizing, quenching, or tempering. Ensure your supplier can provide your forged discs with the necessary heat treatment services.
Quality Certifications of Forged Discs
Quality certifications, such as ISO, ASTM, or ASME, ensure that the forged discs meet specific industry standards and requirements. Look for suppliers with these certifications to guarantee you’re purchasing high-quality products.
Budget and Pricing of Forged Discs
The cost of forged discs can vary depending on the material, size, and additional processing. Compare prices from different suppliers and consider your budget while making your decision. Keep in mind that quality should not be compromised for the sake of lower prices.
Purchasing the correct forged discs is crucial for the success of your project. By understanding the forging process, considering factors like material, size, shape, and quality certifications, and choosing the right supplier, you can ensure that you’re investing in high-quality products that meet your needs. With the right forged discs, you can enhance the performance, durability, and longevity of your applications, contributing to the overall success of your project.
How to select forged discs manufacturer?
Selecting the manufacturer of the right forged disc requires careful consideration of various factors, including quality, experience, capacity, customization, certification, pricing, location, reputation, and additional services offered. By considering all these aspects, you can make an informed decision and choose a reliable and experienced manufacturer that will deliver high-quality forged discs for your project.
Factors to Consider when Selecting a Forged Discs Manufacturer
A. Quality
The quality of the forged discs is of paramount importance. Always choose a manufacturer that adheres to strict quality control standards and utilizes advanced technology to produce high-quality forged discs.
B. Experience
The manufacturer’s experience in the industry is an essential factor to consider. An experienced manufacturer will have the knowledge and expertise to produce high-quality forged discs and meet your requirements.
C. Capacity
The production capacity of the manufacturer should be taken into account. Ensure the manufacturer can handle your order volume, whether a small or large-scale project.
D. Customization
Your project may require customized forged discs with unique specifications. Choose a manufacturer offering customization options, ensuring they meet your specific needs.
E. Certification
Check if the manufacturer holds relevant certifications, such as ISO or AS9100. These certifications are an indication of their commitment to quality and industry standards.
F. Pricing
While pricing should not be the sole determining factor, it is essential to consider the cost of the forged discs. Select a manufacturer that offers competitive pricing without compromising quality.
G. Location
The location of the manufacturer can affect shipping times and logistics costs. Opt for a conveniently located manufacturer that can deliver the forged discs within your desired timeframe.
Evaluating a Manufacturer’s Reputation
A. Customer Reviews
Read through customer reviews and testimonials to understand the manufacturer’s reputation. Positive feedback from satisfied customers is a good indication of the manufacturer’s reliability and commitment to quality.
B. Industry Recognition
Look for manufacturers that have received industry awards or recognition, which indicates their dedication to excellence and innovation in forged discs manufacturing.
Additional Services Offered
A. In-House Testing
Choose a manufacturer that offers in-house testing and inspection services. This ensures that the forged discs meet your specifications and quality requirements before shipping them.
B. On-Time Delivery
On-time delivery is crucial for any project. Select a manufacturer with a track record of delivering orders on time to avoid potential delays or disruptions to your project schedule.
C. After-Sales Support
After-sales support is an essential aspect of any business relationship. Choose a manufacturer that offers excellent customer service and support, including addressing any concerns or issues you may have with the forged discs after delivery.
Why Choose Jihua to Be Your forged disc Supplier?
At Jihua, we pride ourselves on providing top-notch forged discs that meet industry standards. Our state-of-the-art manufacturing facilities and experienced team of engineers ensure that every forged disc we produce is exceptional, with precise dimensions and impeccable surface finish. By choosing Jihua as your forged disc supplier, you can be confident that you are receiving products that will exceed your expectations and stand the test of time.
Wide Range of Materials and Sizes
Our extensive selection of materials and sizes sets us apart from other forged disc suppliers. We offer a diverse range of metals, including stainless steel, alloy steel, carbon steel, and superalloys, to meet the unique requirements of various industries. Our forged discs are available in various diameters and lengths, ensuring we can fulfill any order, no matter how specialized or demanding.
Tailored Solutions for Your Specific Needs
At Jihua, we understand that each customer has unique requirements and challenges. That’s why we offer customized solutions tailored to your specific needs. Our skilled engineers will work closely with you to develop and produce forged discs that meet your specifications. Whether you require a particular material, size, or surface finish, we have the expertise and resources to deliver the perfect solution for your project.
Competitive Pricing and Exceptional Value
We know that cost is crucial when selecting a forged disc supplier. At Jihua, we are committed to providing our customers with competitive pricing without compromising quality. Our streamlined manufacturing processes and extensive industry experience allow us to offer exceptional value, ensuring that you receive the best possible product at a fair price.
Fast Lead Times and Reliable Delivery
In today’s fast-paced business world, time is of the essence. We understand the importance of delivering your forged discs promptly and reliably. Our efficient production processes and well-established logistics network ensure that your order will be completed and delivered on time every time. By choosing Jihua as your forged disc supplier, you can rest assured that your project will stay on track and schedule.
Unparalleled Customer Support
Customer satisfaction is at the core of our business. Our dedicated customer support team is always available to answer any questions or address any concerns. From the moment you place your order to the final delivery of your forged discs, we will be with you every step to ensure a seamless and hassle-free experience.
Environmentally Conscious Manufacturing
At Jihua, we recognize the importance of protecting the environment and are committed to sustainable manufacturing practices. Our eco-friendly production processes and adherence to strict environmental regulations ensure that our forged discs are produced with minimal environmental impact. By choosing Jihua as your forged disc supplier, you can be confident that you are partnering with a company that values and prioritizes environmental responsibility.
Global Presence and Reputation
As a leading global forged disc supplier, Jihua has established a strong presence and reputation in the international market. Our extensive network of satisfied customers and partners is a testament to our commitment to quality, innovation, and customer service. By partnering with Jihua, you can be assured that you are working with a company with the expertise and resources to support your business globally.
State-of-the-Art Research and Development
Innovation is at the heart of our success at Jihua. Our research and development team is constantly exploring new materials, technologies, and manufacturing techniques to improve the performance and durability of our forged discs. By staying at the forefront of industry advancements, we can offer our customers cutting-edge products that set the standard for quality and performance. When you choose Jihua as your forged disc supplier, you can be sure that you are receiving products incorporating the latest industry innovations.
Strict Quality Control and Assurance
To guarantee the highest quality forged discs, we have implemented a rigorous quality control and assurance system at every stage of the production process. From selecting raw materials to the final inspection and testing finished products, our experienced quality control team ensures that every forged disc meets our strict quality standards. By maintaining our unwavering commitment to quality, we can provide our customers with forged discs they can trust to perform reliably in even the most demanding applications.
Certifications and Compliance
As a leading forged disc supplier, Jihua is fully committed to complying with all applicable industry standards and regulations. We hold various certifications, including ISO, demonstrating our dedication to maintaining the highest levels of quality and safety in our products and processes. By choosing Jihua as your forged disc supplier, you can be certain that you are partnering with a company that values compliance and adheres to the strictest industry standards.
Long-Term Partnerships and Collaboration
At Jihua, we believe in building long-lasting relationships with our customers and partners. By fostering a collaborative environment and maintaining open lines of communication, we can better understand your needs and work together to achieve your goals. Our commitment to long-term partnerships ensures we can provide ongoing support and resources to help your business grow and succeed.
Experience and Expertise
With years of experience in the forged disc industry, our team of skilled professionals has the knowledge and expertise to provide you with the best possible solutions for your projects. Our in-depth understanding of various industries unique requirements and challenges enables us to offer expert guidance and advice to help you make the best decisions for your business.
Jihua is the ideal choice for your forged disc supplier due to our commitment to quality, innovation, customer satisfaction, and environmental responsibility. Our extensive range of products, tailored solutions, competitive pricing, fast lead times, and exceptional customer support make us the preferred partner for businesses worldwide. By choosing Jihua as your forged disc supplier, you can be confident that you are working with a company dedicated to your success.
Our forging product types
| Item | Type | Section size/mm | Length/Height mm | Weight/ton |
| 1 | Circle/step axis class | Ø100-Ø1500 | ≤15000 | ≤15 |
| 2 | Flange type | ≤Ø3500 | ≤650 | ≤6 |
| 3 | Cylinder class | Ø200-Ø2000 | ≤3500 | ≤12 |
| 4 | Pie type class | Ø200-Ø2400 | ≤700 | ≤12 |
| 5 | Valve box/valve body type | Ø250-1200 | ≤2000 | ≤12 |
| 6 | Single/double, long/short | Ø200-Ø2000 | ≤10000 | ≤12 |
| Shaft flange type | ||||
| 7 | Cross axis class | ≤Ø2000 | ≤500 | ≤10 |
| 8 | Square class | 100-1500 | ≤10000 | ≤12 |
Export Country For Forged Discs
| MIDDLE EAST | AFRICA | NORTH AMERICA | EUROPE | ASIA | SOUTH AMERICA |
| Saudi Arabia | Nigeria | Usa | Russia | India | Argentina |
| Iran | Algeria | Canada | Norway | Singapore | Bolivia |
| Iraq | Angola | Mexico | Germany | Malaysia | Brazil |
| Uae | South Africa | Panama | France | Indonesia | Chile |
| Qatar | Libya | Costa Rica | Italy | Thailand | Venezuela |
| Bahrain | Egypt | Puerto Rica | Uk | Vietnam | Colombia |
| Oman | Sudan | Trinidad And Tobago | Spain | South Korea | Ecuador |
| Kuwait | Equatorial Guinea | Jamaica | Ukraine | Japan | Guyana |
| Turkey | The Republic Of Congo | Bahamas | Netherland | Sri Lanka | Paraguay |
| Yemen | Gabon | Denmark | Belgium | Maldives | Uruguay |
| Syria | Greece | Bangladesh | |||
| Jordan | Czech Republic | Mayanmar | |||
| Cyprus | Portugal | Taiwan | |||
| Hungary | Cambodia | ||||
| Albania | |||||
| Austria | |||||
| Switzerland | |||||
| Slovakia | |||||
| Finland | |||||
| Ireland | |||||
| Croatia | |||||
| Slovenia | |||||
| Malta |