Forgings

How the forging process scheme of forgings is determined?

Economic analysis of forging processing aims to explore the best technical solution and pursue the maximum economic effect. In any production process, it is not only necessary to formulate the technological process, and determine the technological parameters and equipment but also to discuss the economic effects.
The principle for determining the forging process is to create the most material wealth with the minimum labor consumption. Process optimization is to find a minimum value in the total consumption of materials, equipment, energy, and labor while ensuring product quality and quantity. For the forging process, it can be specified as follows: high dimensional accuracy of forgings, satisfactory organization, and performance, low raw material consumption, small equipment investment, simple tools, low energy consumption, low labor intensity, and no environmental pollution.

The technical and economic effects are carried out using a comparative approach. When comparing process plans, there may be more than two plans. To make the analysis conclusion correct and reliable, the exhaustive method should be used to list possible or alternative plans. Therefore, conducting a forging process analysis is necessary, exploring various processes and schemes, preparing conditions for technical and economic analysis, and selecting the best process scheme. The task of general process analysis can be summarized as follows: proposing various process plans that can be adopted based on the functional characteristics, materials, shapes, dimensional accuracy, quality requirements, and production batch of forgings, as well as existing or available equipment, devices, tools, energy, inspection methods, management levels, and personnel qualities.
When conducting a process analysis, the following questions must be considered and answered:

• (1) Whether it can meet the functions of forgings;
• (2) Whether the technical conditions and quality standards of the drawings can be met;
• (3) Whether the structure of the forging is reasonable and whether there are redundant dressings;
• (4) Whether the machining allowance can be reduced;
• (5) Whether the deformation force or deformation work can be reduced;
• (6) Whether the metal flow line meets the requirements;
• (7) Whether there is any omission in the quality assurance process;
• (8) Whether the processes and steps have been minimized;
• (9) Whether the materials are fully utilized, whether it is possible to forge with other parts, and whether there are many parts in one the first mock examination or one blank;
• (10) Have considered advanced processes such as cold forging, precision forging, rolling, partial die forging, segmented die forging, combined die forging, forging, and welding.

Steps of forging process analysis

Process analysis takes specific forgings as the object, comprehensively utilizing knowledge of metal pressure processing principles, forging technology, metallurgy and heat treatment, forging equipment and automation, and factory production practices and starting from analyzing the functions and technical requirements of parts, exploring various possible deformation methods, designing reasonable forging structures, determining appropriate machining allowances, tolerances, and process dressing, and drawing forging drawings. Calculate the force required for deformation based on the forging’s shape, size, and deformation mode, and select the leading forging equipment. Determine the heating temperature according to the forging material and deformation method, and select the heating method and equipment. The blanking equipment is selected based on the forging equipment type, deformation method, and blank size. Determine the process route according to the quality requirements of forgings, and select equipment such as trimming, correction, fine pressing, heat treatment, cleaning, inspection, and flaw detection. Determine the production rhythm and productivity based on the production batch, then calculate the equipment amount. Calculate various consumption data based on equipment performance characteristics and productivity, such as material, power, blanking, auxiliary materials, and mold consumption. Based on the selected process, considering the production organization, and equipment characteristics, determine the required workshop area for the production and the number of production workers, auxiliary workers, technicians, and management personnel, and then analyze the advantages and disadvantages of various processes, such as labor conditions, environmental protection, and their technical and labor skills requirements.
It should be pointed out that before obtaining alternative process plans, technically unreliable processes need to be screened and eliminated. The so-called unreliable process includes the following aspects: inability to complete the forming of forgings; The dimensional accuracy cannot meet the drawing requirements; The metal flow line is unreasonable or cannot meet the requirements of the part for the metal flow line; Unable to meet performance requirements such as strength, stiffness, and hardness of parts; Unable to meet the requirements for quality and dimensional tolerances in the use or subsequent processing of parts; Unable to obtain the required equipment or molds, or the necessary power, fuel, raw materials, and auxiliary materials; Serious public hazards or damage to the health of operators that cannot be prevented or prevented or due preventive measures cannot be taken.
Process analysis is a system engineering problem. Although analogy and inference are still based on experience and are characterized by the personal mental work of a craftsman, it is required that those engaged in this work be familiar with existing production methods and master the characteristics, scope of application, and limitations of various process schemes. Be able to calculate various technical parameters correctly, understand the current situation, trends, and development trends of forging production at home and abroad, and infer and predict based on actual conditions.
Through the above analysis and comparison process, we comprehensively understand the processing methods for specific forgings. If the analysis is based on existing knowledge and experience, several proposed process plans will be limited to existing production methods. On this basis, further thinking and new ideas will be proposed. Aiming at the inherent shortcomings of existing schemes, it is possible to improve or change forgings and conceive new process schemes in the case of deformation methods, reduced processes, energy conservation, and material conservation. The new concept must go through the above procedures to calculate various technical data to form a complete process plan.

What are industrial forgings?

Industrial forgings refer to workpieces or blanks obtained by forging and deforming metal blanks. Applying pressure to a metal blank to produce plastic deformation can change its mechanical properties.

What are the different types of industrial forgings?

Types of forgings

• Forged Axes: These specialized tools are crafted using high-quality steel and feature a robust design suitable for various applications, including woodworking, firefighting, and outdoor activities.
• Forged Bars: Forged bars are available in various shapes and sizes, such as round, square, and flat. They are used in numerous industries, including aerospace, automotive, and construction.
• Forged Blocks: These large, rectangular-shaped forgings are used for manufacturing heavy machinery, die and mold equipment, and parts for the automotive and aerospace industries.
• Forged Bushes: Forged bushes are cylindrical components that reduce friction in rotating applications. They are commonly used in automotive, construction, and heavy machinery industries.
• Forged Caps: These components are typically used to close off pipes and tubes in high-pressure applications. Forged caps can be found in various industries, such as oil and gas, petrochemical, and power generation.
• Forged Crane Wheels: Forged crane wheels are essential for smoothly operating overhead cranes, gantry cranes, and other lifting equipment. They are designed to withstand heavy loads and harsh environments.
• Forged Cylinders: These cylindrical-shaped forgings are widely used in hydraulic and pneumatic systems, providing high strength and durability. Forged cylinders can be found in the automotive, aerospace, and heavy machinery industries.
• Forged Discs: Forged discs are round, flat components often used as base plates, flanges, and wear parts. They are utilized in various industries, including aerospace, automotive, and power generation.
• Forged Gears: Forged gears offer superior strength and wear resistance compared to cast or machined gears. They are essential in the automotive, aerospace, and heavy machinery industries.
• Forged Hubs: These central components connect shafts, wheels, and other rotating parts. Forged hubs are used in automotive, aerospace, and industrial equipment applications.
• Forged Lateral Tees: Forged lateral tees are specialized pipe fittings used to connect and branch off pipelines in various industries, such as oil and gas, petrochemical, and water treatment.
• Forged Nozzles: These components direct the flow of fluid or gas in various applications. Forged nozzles are commonly used in the oil and gas, petrochemical, and power generation industries.
• Forged Pipes: Forged pipes are high-strength tubes designed for transporting fluids and gases under high pressure. They are commonly used in the oil and gas, petrochemical, and power generation industries.
• Forged Rings: Forged rings are donut-shaped components used in various applications, such as bearings, gears, and flanges. They are widely utilized in the aerospace, automotive, and heavy machinery industries.
• Forged Rotors: These essential components are used in rotating machinery, such as turbines, compressors, and pumps. Forged rotors offer high strength and durability in demanding applications.
• Forged Shafts: Forged shafts are cylindrical components that transmit power and torque in rotating equipment. They are used in various industries, including automotive, aerospace, and heavy machinery.
• Forged Sleeves: These cylindrical components are designed to provide wear resistance and protect shafts in rotating equipment. Forged sleeves are used in automotive, aerospace, and industrial machinery applications.
• Forged Stub Ends: Forged stub ends are pipe fittings used in conjunction with lap joint flanges to facilitate easy assembly and disassembly of piping systems. They are commonly used in the oil and gas, petrochemical, and power generation industries.
• Forged Valve Bodies: These critical components house the internal parts of valves and control the flow of fluids or gases in various industries, such as oil and gas, petrochemical, and power generation.
• Forged Valve Bonnets: Forged valve bonnets are the top part of a valve assembly that encloses the valve stem and other internal components. They are used in various industries, including oil and gas, petrochemical, and power generation.
• Forged Wide Electrical Axis: These specialized components are used in electrical power transmission systems and provide support for heavy loads and high torques. Forged wide electrical axes are used in various industries, such as power generation, telecommunications, and electrical utilities.
• Rolled Rings: Rolled rings are circular components manufactured through the process of ring rolling. They are used in various applications, including bearings, gears, and flanges, and are utilized in the aerospace, automotive, and heavy machinery industries.
• Forged Wyes: Forged wyes are Y-shaped pipe fittings used to connect and branch off pipelines in various industries, such as oil and gas, petrochemical, and water treatment.
• Forged Reducers: These components are used to decrease the size of pipes in a piping system, ensuring smooth flow and pressure control. Forged reducers are commonly used in the oil and gas, petrochemical, and power generation industries.
• Forged Tees: Forged tees are T-shaped pipe fittings used to connect and branch off pipelines in various industries, such as oil and gas, petrochemical, and water treatment.
• Forged Cross: Forged crosses are X-shaped pipe fittings used to connect and branch off pipelines in various industries, such as oil and gas, petrochemical, and water treatment.
• Forged Hemispherical head: These components are used in pressure vessels and tanks, providing a durable and efficient design for containing high-pressure fluids and gases. Forged hemispherical heads are utilized in the oil and gas, petrochemical, and power generation industries.
• Forged Olets: Forged olets are specialized pipe fittings that provide an outlet for a run pipe from a larger pipe. They are used in various industries, such as oil and gas, petrochemical, and water treatment.

The characteristics of forging products

The forging products of the forging plant are plastically deformed by forging processing. Forging processing is a processing method that uses external force to make the raw material of forging produce plastic deformation and obtain the required size, shape, and performance of the blank or part of forging. Through forging processing can eliminate the metal in the smelting process produced by the cast state sparse and other defects, optimize the microstructure while preserving the integrity of the metal forging flow line, greatly enhancing the performance of forgings in use.
Forging is one of the main methods for producing blanks and parts in machinery manufacturing, often divided into free forging, die forging, etc. Compared with other processing methods, forging processing has the following characteristics:

• Improve the internal organization of forgings, and improve the mechanical properties. Forging billet after forging processing, its organization and performance are improved and enhanced; forging processing can eliminate the metal ingot internal pores, shrinkage, and dendritic crystal defects, and due to the plastic deformation of metal and recrystallization, can make the coarse grain refinement, dense metal organization, thereby improving the mechanical properties of forgings. In the design of the parts, the correct choice of parts of the direction of force and fiber organization can improve the impact resistance of forgings.
• The high utilization rate of the material. Metal plastic forming mainly relies on the relative position of the shape of the metal tissue rearrangement without the need to remove the metal.
• Higher productivity. The forging process is generally used for forming by the press and forging hammer.
• Higher precision of the blank or forging part. Applying advanced technology and equipment can achieve less cutting or cutting-free processing.
• The metal material used in forging should have good plasticity so that it can produce plastic deformation without rupture under external forces. Commonly used metal materials, cast iron is brittle, plasticity could be better, and cannot be used for forging. Steel and non-ferrous metals such as copper, aluminum, and their alloys can be processed under pressure in a cold or hot state.
• Not suitable for forming the more complex shape of forgings. Forging processing is formed in the solid state; compared with casting, the flow of metal is restricted and generally needs a heating and other process measures to achieve. Manufacturing complex shapes, especially with complex internal cavities of parts or blanks, is more complicated.

Because forging has the above characteristics, the essential parts that bear impact or alternating stress (such as transmission spindle, gear ring, connecting rod, track wheel, etc.) should be processed by forging blanks, so forging processing in machinery manufacturing, mining, light industry, heavy industry, and other industries are widely used.

Materials of Forgings

Forgings are used in many different industries and can be made from a variety of materials. Carbon steel, alloy steel, stainless steel and nickel alloys are common materials used in forging production. These materials are not only used because they provide strength but also because they offer corrosion resistance in different environments. The material depends on the application and environment of the forging. Some common materials include carbon steel, stainless steel, nickel alloys, monel (nickel-copper), inconel (nickel-chromium), hastelloy (beryllium) and titanium.

Different types of forging materials and their properties in brief:

Carbon steel forgings

Carbon steel forgings are the most commonly used type of forging in the world. These forgings are used in low pressure and low temperature applications, such as oil and gas pipelines. Carbon steel is a malleable metal that can be bent into various shapes without losing its strength. The most common types of carbon steel are carbon steel plate, sheet, tube and pipe products with high strength properties at room temperatures or lower operating temperatures; stainless steels can also be rolled or extruded into tubular products having high strength at moderate temperatures (up to about 250° F).

Alloy steel forgings

Alloy steel is a steel that is alloyed with a variety of elements in total amounts between 1.0% and 50% by weight to improve its mechanical properties. Alloying elements are added for their positive effect on the microstructure of the resulting steel, which allows it to achieve greater strength than an equivalent standard grade or carbon steel. The alloying process involves taking a sample of the base material, heating it up until it becomes liquid and then adding different elements that will make up the final alloy’s makeup. The mixture must be carefully balanced so that no single element has too much influence over another; otherwise, some may become dominant and change the properties of what was once just an ordinary piece of metal into something else entirely.

Stainless steel forgings

Stainless steel is a hard, corrosion-resistant metal. It’s used in many different industries and often used for food and beverage applications. Stainless steel is also often used for medical applications due to its durability and resistance to wear. Forgings are usually made from stainless steel because it does not rust or corrode easily, making them ideal for use with liquids such as water. This material can be welded together using oxyacetylene torches or electric arc welding machines (EAWs).

Low temperature carbon steel forgings

Low temperature carbon steel forgings are a type of material that can be used for the construction and installation of piping systems. These forgings are typically made from low carbon content steel or cast iron, which has been hardened by heat treatment. Low temperature carbon steel forgings are often chosen because they’re inexpensive, durable, and easy to install. Because of their design and relatively low cost, these types of forgings have become very popular among homeowners who want to take advantage of DIY plumbing projects around their homes. In terms of disadvantages, one major drawback is that low temperature carbon steel forgings aren’t suitable for use with high pressure systems (such as those found in industrial settings). As such they’re best suited only for household purposes where there isn’t much pressure involved.*

Nickel alloy forgings

Nickel alloy forgings are used where high temperature, high pressure and corrosion resistance are required. Nickel alloy forgings are used in the oil and gas industry, petrochemical industry and nuclear industry.

Monel Forgings

Monel is a nickel-copper alloy, with nickel as the main alloying element. It was one of the first alloys to be registered under the new US patent law. Monel has excellent resistance to corrosion in a wide range of industrial and chemical environments. Monel is resistant to acids, alkalies, salt water, and organic solvents. The addition of copper improves machinability and also significantly lowers the temperature at which galling occurs between dissimilar metals such as steel spindles and cast iron journals when rotating at high speeds. Monel alloys are largely immune from crevice corrosion (pitting) in chloride environments due to their high molybdenum content (6%–12%). There are seven types of Monel in use today: Types 400 (UNS N04400), K-500 (UNS N05500), BX C-276 (UNS N06600), C-276 (UNS N06625), Alloy 20/Nimonic 90®, Alloy 300/Inconel 600® and Alloy 800/CuproNickel®and two more exotic versions not yet commercially available but used in special applications: Type 410LN™and Type 430L™

Inconel Forgings

The nickel-chromium alloy is made of a combination of nickel, chromium and iron. It is non-magnetic and resistant to corrosion. It can be used in high temperature applications up to 1,650 degrees Celsius (3,000 degrees Fahrenheit). Inconel forgings are also used in chemical processing applications such as oil refining and petrochemical plants because the material does not corrode under stress or exposure to chemicals.

Hastelloy Forgings

Hastelloy Forgings are used for a variety of purposes, such as in the process, chemical, food and pharmaceutical industries.

Titanium Forgings

Titanium forgings are used in high temperature applications. Titanium forgings are used in aerospace and military applications, chemical processing applications and the oil and gas industry. Titanium has many properties which make it an ideal material for forgings:

• It has high strength-to-weight ratio – about twice as strong as steel;
• It’s corrosion resistant to many chemicals;
• It can withstand temperatures up to 2000°F (1100°C).

When purchasing forgings, in addition to physical measurement and bolt hole alignment, forging materials must also be considered. The choice of forging material is determined by the chemical composition and physical properties of the metal. You can take a look at the combination standard to guide your decision.

Chemical Composition for Forgings

Chemical Composition for Carbon steel

Gr.	C	Mn	P	S	Si	Cr	Mo	Ni	Cu	Others
			max	max
WPB (1 2 3 4 5)	0.3	0.29	0.05	0.058	0.1	0.4	0.15	0.4	0.4	V 0.08
	max	1.06			min	max	max	max	max	max
WPC (2 3 4 5)	0.35	0.29	0.05	0.058	0.1	0.4	0.15	0.4	0.4	V 0.08
	max	1.06			min	max	max	max	max	max
WP1	0.28	0.3	0.045	0.045	0.1		0.44
	max	0.9			0.5		0.65
WP12 CL1	0.05	0.3	0.045	0.045	0.6	0.8	0.44
	0.2	0.8			max	1.25	0.65
WP12 CL2	0.05	0.3	0.045	0.045	0.6	0.8	0.44
	0.2	0.8			max	1.25	0.65
WP11 CL1	0.05	0.3	0.03	0.03	0.5	1	0.44
	0.15	0.6			1	1.5	0.65
WP11 CL2	0.05	0.3	0.04	0.04	0.5	1	0.44
	0.2	0.8			1	1.5	0.65
WP11 CL3	0.05	0.3	0.04	0.04	0.5	1	0.44
	0.2	0.8			1	1.5	0.65
WP22 CL1	0.05	0.3	0.04	0.04	0.5	1.9	0.87
	0.15	0.6			max	2.6	1.13
WP22 CL3	0.05	0.3	0.04	0.04	0.5	1.9	0.87
	0.15	0.6			max	2.6	1.13
WP5 CL1	0.15	0.3	0.04	0.03	0.5	4	0.44
	max	0.6			max	6	0.65
WP5 CL3	0.15	0.3	0.04	0.03	0.5	4	0.44
	max	0.6			max	6	0.65
WP9 CL1	0.15	0.3	0.03	0.03	1	8	0.9
	max	0.6			max	10	1.1
WP9 CL3	0.15	0.3	0.03	0.03	1	8	0.9
	max	0.6			max	10	1.1
WPR	0.2	0.4	0.045	0.05				1.6	0.75
	max	1.06						2.24	1.25

Notes:

• Fittings made from bar or plate may have 0.35 max carbon.
• Fittings made from forgings may have 0.35 max Carbon and 0.35 max Silicon with no minimum.
• For each reduction of 0.01% below the specified Carbon maximum, an increase of 0.06% Manganese above the specified maximum will be permitted, up to a maximum of 1.35%.
• The sum of Copper, Nickel, Niobium, and Molybdenum shall not exceed 1.00%.
• The sum of Niobium and Molybdenum shall not exceed 0.32%.
• Applies both to heat and product analyses.

Chemical Composition for stainless steel

Grade	C, ≤	Mn, ≤	P, ≤	S, ≤	Si, ≤	Cr	Ni	Mo	N, ≤	Other Elements, ≤
304	0.08	2.00	0.045	0.03	1.00	18.0-20.0	8.0-11.0	–	–	–
304L	0.03	2.00	0.045	0.03	1.00	18.0-20.0	8.0-12.0	–	–	–
316	0.08	2.00	0.045	0.030	1.00	16.0-18.0	10.0-14.0	2.00-3.00	–	–
316L	0.03	2.00	0.045	0.030	1.00	16.0-18.0	10.0-14.0	2.00-3.00	–	–
321	0.08	2.00	0.045	0.03	1.00	17.0-19.0	9.0-12.0	–	0.10	≥ Ti 5×(C+N), ≤ 0.70
201	0.15	5.50-7.50	0.06	0.03	1.00	16.0-18.0	3.5-5.5	–	0.25	–
202	0.15	7.50-10.00	0.06	0.03	1.00	17.0-19.0	4.0-6.0	–	0.25	–
205	0.12-0.25	14.0-15.5	0.06	0.03	1.00	16.5-18.0	1.0-1.7	–	0.32-0.40	–
301	0.15	2.00	0.045	0.03	1.00	16.0-18.0	6.0-8.0	–	0.10	–
301L	0.03	2.00	0.045	0.03	1.00	16.0-18.0	6.0-8.0	–	0.20	–
301LN	0.03	2.00	0.045	0.03	1.00	16.0-18.0	6.0-8.0	–	0.07-0.20	–
302	0.15	2.00	0.045	0.03	0.75	17.0-19.0	8.0-10.0	–	0.10	–
302B	0.15	2.00	0.045	0.03	2.00-3.00	17.0-19.0	8.0-10.0	–	0.10	–
303	0.15	2.00	0.2	≥0.15	1.00	17.0-19.0	8.0-10.0	–	–	–
303Se	0.15	2.00	0.2	0.06	1.00	17.0-19.0	8.0-10.0	–	–	Se 0.15
304H	0.04-0.10	2.00	0.045	0.03	0.75	18.0-20.0	8.0-10.5	–	–	–
304N	0.08	2.00	0.045	0.03	1.00	18.0-20.0	8.0-11.0	–	0.10-0.16	–
304LN	0.03	2.00	0.045	0.03	1.00	18.0-20.0	8.0-11.0	–	0.10-0.16	–
305	0.12	2.00	0.045	0.03	1.00	17.0-19.0	11.0-13.0	–	–	–
308	0.08	2.00	0.045	0.03	1.00	19.0-21.0	10.0-12.0	–	–	–
309	0.2	2.00	0.045	0.03	1.00	22.0-24.0	12.0-15.0	–	–	–
309S	0.08	2.00	0.045	0.03	1.00	22.0-24.0	12.0-15.0	–	–	–
309H	0.04-0.10	2.00	0.045	0.03	0.75	22.0-24.0	12.0-15.0	–	–	–
309Cb	0.08	2.00	0.045	0.03	1.00	22.0-24.0	12.0-16.0	–	–	≥ Cb 10 x C, ≤1.10
309HCb	0.04-0.10	2.00	0.045	0.03	0.75	22.0-24.0	12.0-16.0	–	–	≥ Cb 10 x C, ≤1.10
310	0.25	2.00	0.045	0.03	1.5	24.0-26.0	19.0-22.0	–	–	–
310S	0.08	2.00	0.045	0.03	1.5	24.0-26.0	19.0-22.0	–	–	–
310H	0.04-0.10	2.00	0.045	0.03	0.75	24.0-26.0	19.0-22.0	–	–	–
310Cb	0.08	2.00	0.045	0.03	1.5	24.0-26.0	19.0-22.0	–	–	≥ Cb 10 x C, ≤ 1.10
310 MoLN	0.02	2.00	0.03	0.01	0.5	24.0-26.0	20.5-23.5	1.60-2.60	0.09-0.15	–
314	0.25	2.00	0.045	0.03	1.50-3.00	23.0-26.0	19.0-22.0	–	–	–
316H	0.04-0.10	2.00	0.045	0.03	0.75	16.0-18.0	10.0-14.0	2.00-3.00	–	–
316Ti	0.08	2.00	0.045	0.03	1.00	16.0-18.0	10.0-14.0	2.00-3.00	0.1	≥ Ti 5 × (C + N), ≤0.70
316Cb	0.08	2.00	0.045	0.03	1.00	16.0-18.0	10.0-14.0	2.00-3.00	0.1	≥ Cb 10 × C, ≤ 1.10
316N	0.08	2.00	0.045	0.03	1.00	16.0-18.0	10.0-14.0	2.00-3.00	0.10-0.16	–
316LN	0.03	2.00	0.045	0.03	1.00	16.0-18.0	10.0-13.0	2.00-3.00	0.10-0.16	–
317	0.08	2.00	0.045	0.03	1.00	18.0-20.0	11.0-15.0	3.0-4.0	0.1	–
317L	0.03	2.00	0.045	0.03	0.75	18.0-20.0	11.0-15.0	3.0-4.0	0.1	–
317LM	0.03	2.00	0.045	0.03	0.75	18.0-20.0	13.5-17.5	4.0-5.0	0.2	–
317LMN	0.03	2.00	0.045	0.03	0.75	17.0-20.0	13.5-17.5	4.0-5.0	0.10-0.20	–
317LN	0.03	2.00	0.045	0.03	0.75	18.0-20.0	11.0-15.0	3.0-4.0	0.10-0.22	–
321	0.08	2.00	0.045	0.03	1.00	17.0-19.0	9.0-12.0	–	0.1	≥ Ti 5 × (C + N), ≤ 0.70
321H	0.04-0.10	2.00	0.045	0.03	0.75	17.0-19.0	9.0-12.0	–	–	≥ Ti 4 × (C + N), ≤ 0.70
334	0.08	1.00	0.03	0.015	1.00	18.0-20.0	19.0-21.0	–	–	Al 0.15-0.60, Ti 0.15-0.60
347	0.08	2.00	0.045	0.03	1.00	17.0-19.0	9.0-12.0	–	–	≥ Cb 10 × C, ≤ 1.00
347H	0.04-0.10	2.00	0.045	0.03	0.75	17.0-19.0	9.0-13.0	–	–	≥ Cb 8 × C, ≤ 1.00
347LN	0.005-0.020	2.00	0.045	0.03	1.00	17.0-19.0	9.0-13.0	–	0.06-0.10	Cb 0.20-0.50, 15 × C ≥
348	0.08	2.00	0.045	0.03	1.00	17.0-19.0	9.0-12.0	–	–	Cb 10×C-1.10, Ta 0.10, Co 0.20
348H	0.04-0.10	2.00	0.045	0.03	0.75	17.0-19.0	9.0-13.0	–	–	(Cb + Ta) 8×C ≥ , 1.00 ≤, Ta 0.10, Co 0.20
2205	0.03	2.00	0.03	0.02	1.00	22.0-23.0	4.5-6.5	3.0-3.5	0.14-0.20	–
2304	0.03	2.5	0.04	0.03	1.00	21.5-24.5	3.0-5.5	0.05-0.60	0.05-0.60	–
255	0.04	1.5	0.04	0.03	1.00	24.0-27.0	4.5-6.5	2.9-3.9	0.10-0.25	Cu 1.50-2.50
2507	0.03	1.2	0.035	0.02	0.8	24.0-26.0	6.0-8.0	3.0-5.0	0.24-0.32	Cu ≤0.50
329	0.08	1.00	0.04	0.03	0.75	23.0-28.0	2.0-5.00	1.00-2.00	–	–
403	0.15	1.00	0.04	0.03	0.5	11.5-13.0	–	–	–	–
405	0.08	1.00	0.04	0.03	1.00	11.5-14.5	≤0.5	–	–	Al 0.10-0.30
410	0.08-0.15	1.00	0.04	0.03	1.00	11.5-13.5	–	–	–	–
410S	0.08	1.00	0.04	0.03	1.00	11.5-13.5	≤0.6	–	–	–
414	0.15	1.00	0.04	0.03	1.00	11.5-13.5	1.25-2.50	–	–	–
416	0.15	1.25	0.06	≥0.15	1.00	12.0-14.0	–	–	–	–
416Se	0.15	1.25	0.06	≥0.06	1.00	12.0-14.0	–	–	–	Se 0.15
420	0.15, ≥	1.00	0.04	0.03	1.00	12.0-14.0	–	–	–	–
420F	0.30-0.40	1.25	0.06	≥0.15	1.00	12.0-14.0	≤0.5	–	–	Cu 0.60
420FSe	0.20-0.40	1.25	0.06	0.15	1.00	12.0-14.0	≤0.5	–	–	Se 0.15; Cu 0.60
422	0.20-0.25	0.50-1.00	0.025	0.025	0.5	11.0-12.5	0.50-1.00	0.90-1.25	–	V (0.20-0.30), W (0.90-1.25)
429	0.12	1.00	0.04	0.03	1.00	14.0-16.0	–	–	–	–
430	0.12	1.00	0.04	0.03	1.00	16.0-18.0	–	–	–	–
430F	0.12	1.25	0.06	≥0.15	1.00	16.0-18.0	–	–	–	–
430FSe	0.12	1.25	0.06	0.06	1.00	16.0-18.0	–	–	–	Se 0.15
439	0.03	1.00	0.04	0.03	1.00	17.0-19.0	≤0.5	–	0.03	≥ Ti [0.20+4(C+N)], ≤ 1.10; Al 0.15
431	0.2	1.00	0.04	0.03	1.00	15.0-17.0	1.25-2.50	–	–	–
434	0.12	1.00	0.04	0.03	1.00	16.0-18.0	–	0.75-1.25	–
436	0.12	1.00	0.04	0.03	1.00	16.0-18.0	–	0.75-1.25	–	≥ Cb 5×C, ≤ 0.80
440A	0.60-0.75	1.00	0.04	0.03	1.00	16.0-18.0	–	≤0.75	–	–
440B	0.75-0.95	1.00	0.04	0.03	1.00	16.0-18.0	–	≤0.75	–	–
440C	0.95-1.20	1.00	0.04	0.03	1.00	16.0-18.0	–	≤0.75	–	–
440F	0.95-1.20	1.25	0.06	0.15	1.00	16.0-18.0	≤0.5	–	–	Cu ≤0.60
440FSe	0.95-1.20	1.25	0.06	0.06	1.00	16.0-18.0	≤0.5	–	–	Se ≤0.15; Cu ≤0.60
442	0.2	1.00	0.04	0.04	1.00	18.0-23.0	≤0.6	–	–
444	0.025	1.00	0.04	0.03	1.00	17.5-19.5	≤1.00	1.75-2.50	0.035	Ti+Cb 0.20+4 × (C+N)-0.80
446	0.2	1.5	0.04	0.03	1.00	23.0-27.0	≤0.75	–	0.25	–
800	0.1	1.5	0.045	0.015	1.00	19.0-23.0	30.0-35.0	–	–	Cu 0.75; ≥ FeH 39.5; Al 0.15-0.60
800H	0.05-0.10	1.5	0.045	0.015	1.00	19.0-23.0	30.0-35.0	–	–	Cu 0.75; ≥ FeH 39.5; Al 0.15-0.60
904L	0.02	2.00	0.045	0.035	1.00	19.0-23.0	23.0-28.0	4.00-5.00	0.1	Cu 1.00-2.00
Alloy 20	0.07	2.00	0.045	0.035	1.00	19.0-21.0	32.0-38.0	2.00-3.00	–	Cu 3.0-4.0; ≥ Nb 8 × C; ≤1.00
XM-1	0.08	5.0-6.5	0.04	0.18-0.35	1.00	16.00-18.0	5.0-6.5	–	–	Cu 1.75-2.25
XM-2	0.15	2.00	0.05	0.11-0.16	1.00	17.0-19.0	8.0-10.0	0.40-0.60	–	Al 0.60-1.00
XM-5	0.15	2.5-4.5	0.2	≥0.25	1.00	17.0-19.0	7.0-10.0	–	–	–
XM-6	0.15	1.50-2.50	0.06	≥0.15	1.00	12.0-14.0	–	–	–	–
XM-10	0.08	8.0-10.0	0.045	0.03	1.00	19.0-21.5	5.5-7.5	–	0.15-0.40	–
XM-11	0.04	8.0-10.0	0.045	0.03	1.00	19.0-21.5	5.5-7.5	–	0.15-0.40	–
XM-15	0.08	2.00	0.03	0.03	1.50-2.50	17.0-19.0	17.5-18.5	–	–	–
XM-17	0.08	7.50-9.00	0.045	0.03	0.75	17.5-22.0	5.0-7.0	2.00-3.00	0.25-0.50	–
XM-18	0.03	7.50-9.00	0.045	0.03	0.75	17.5-22.0	5.0-7.0	2.00-3.00	0.25-0.50	–
XM-19	0.06	4.0-6.0	0.045	0.03	1.00	20.5-23.5	11.5-13.5	1.50-3.00	0.20-0.40	Cb 0.10-0.30, V 0.10-0.30
XM-21	0.08	2.00	0.045	0.03	0.75	18.0-20.0	8.0-10.5	–	0.16-0.30	–
XM-27	0.01	0.4	0.02	0.02	0.4	25.0-27.5	≤0.5	0.75-1.50	0.015	Cu 0.20; Cb 0.05-0.20; (Ni + Cu) 0.50
XM-33	0.06	0.75	0.04	0.02	0.75	25.0-27.0	≤0.5	0.75-1.50	0.04	Cu 0.20; Ti 0.20-1.00; ≥ Ti 7(C+N)
XM-34	0.08	2.5	0.04	≥0.15	1.00	17.5-19.5	–	1.50-2.50	–	–
PH 13-8Mo	0.05	0.2	0.01	0.008	0.1	12.25-13.25	7.5-8.5	–	–	–
15-5 PH	0.07	1	0.04	0.03	1	14.0-15.5	3.5-5.5	–	–	2.5-4.5 Cu; 0.15-0.45 Nb
17-4 PH	0.07	1	0.04	0.03	1	15.5-17.5	3.0-5.0	–	–	3.0-5.0 Cu; 0.15-0.45 Nb
17-7 PH	0.09	1	0.04	0.04	1	16.0-18.0	6.5-7.75	–	–	0.75-1.5 Al

Chemical Composition for nickel alloy

Chemical Composition for titanium & titanium alloy

Grade No.	Fe max	O max	N max	C max	H max	Pd	Al	V	Mo	Ni	Elong’n	Rp0.2	Rm
	wt%	wt%	wt%	wt%	wt%	wt%	wt%	wt%	wt%	wt%	%	MPa	MPa
Grade 1	0.2	0.18	0.03	0.1	0.015						24	170-310	240
Grade 2	0.3	0.25	0.03	0.1	0.015						20	275-450	345-480
Grade 3	0.25	0.3	0.05	0.1	0.015						18	360-480	480-700
Grade 4	0.5	0.4	0.05	0.1	0.015						15	500-530	600-680
Grade 5	0.4	0.2	0.05	0.1	0.015		5.5-6.7				10	800-1100	890-1400
Grade 6				0.1							16	780-820	820-860
Grade 7	0.3	0.25	0.03	0.1	0.015	0,12-0,25					20	275-450**	345
Grade 9	0.25	0.15	0.02	0.05	0.015		2,5-3,05				15	550	650
Grade 11	0.2	0.18	0.03	0.1	0.015	0.12					24	170-310**	240
						-0.25
Grade 12	0.3	0.25	0.03	0.1	0.015				0.3	0.8	25	414-460	499-600
Grade 13										0.5
Grade 14										0.5
Grade 15										0.5
Grade 16						0.04-0.08					27	345	485
Grade 17		0.18				0.04-0.08					35	206	345
Grade 18						0.04-0.08	3	2.5	4
Grade 19							3	8	4
Grade 20						0.04-0.08	3	8	4
Grade 21							3		15		15-8	880-1250	915-1350

Chemical Composition for copper and copper based alloys

Chemical Composition for hastelloy alloy

Hastelloy Alloy*	C%	Co%	Cr%	Mo%	V%	W%	Ai%	Cu%	Nb %	Ti%	Fe%	Ni%	Other%
Hastelloy B	0.1	1.25	0.6	28	0.3	–	–	–	–	–	5.5	rest/bal	Mn 0.80; Si 0.70
Hastelloy B2 / Hastelloy B-2	0.02	1	1	26.0-30.0	–	–	–	–	–	–	2	rest/bal	Mn 1.0, Si 0.10
Hastelloy C	0.07	1.25	16	17	0.3	40	–	–	–	–	5.75	rest/bal	Mn 1.0; Si 0.70
Hastelloy C4 / Hastelloy C-4	0.015	2	14.0-18.0	14.0-17.0	–	–	–	–	–	0..70	3	rest/bal	Mn 1.0 ; Si 0.08
Hastelloy C276 / Hastelloy C-276	0.02	2.5	14.0-16.5	15.0-17.0	0.35	3.0-4.5	–	–	–	–	4.0-7.0	rest/bal	Mn 1.0; Si 0.05
Hastelloy F	0.02	1.25	22	6.5	–	0.5	–	–	2.1	–	21	rest/bal	Mn 1.50; Si 0.50
Hastelloy G	0.05	2.5	21.0-23.5	5.5-7.5	–	1	–	1.5-2.5	1.7-2.5	–	18.0-21.0	rest/bal	Mn 1.0-2.0; P0.04; Si 1.0;
Hastelloy G2 / Hastelloy G-2	0.03	–	23.0-26.0	5.0-7.0	–	–	–	0.70-1.20	–	0.70-1.50	rest/bal	47.0-52.0	Mn 1.0; Si 1.0
Hastelloy N	0.06	0.25	7	16.5	–	0.2	–	0.1	–	–	3	rest/bal	Mn 0.40; Si 0.25; B 0.01
Hastelloy S	0.02	2	15.5	14.5	0.6	1	0.2	–	–	–	3	rest/bal	Mn 0.50; Si 0.40; B0.0009; La 0.02
Hastelloy W	0.06	1.25	5	24.5	–	–	–	–	–	–	5.5	rest/bal	Mn 0.050; Si 0.50
Hastelloy X	0.1	1.5	22	9	–	0.6	–	–	–	18.5	–	rest/bal	Mn 0.6; Si 0.60

Chemical Composition for monel

Grade

C%

Co%

Cr%

Mo%

Ni%

V%

W%

Ai%

Cu%

Nb/Cb Ta%

Ti%

Fe%

Sonstige Autres-Other %

Monel 400

0.12

–

–

–

65

–

–

–

32

–

–

1.5

Mn 1.0

Monel 401

0.1

–

–

–

43

–

–

–

53

–

–

0.75

Si 0.25; Mn 2.25

Monel 404

0.15

–

52.0-57.0

–

–

0.05

rest/bal

–

–

0.5

Mn 0.10; Si 0.10;S o.024

Monel 502

0.1

–

–

–

63.0-17.0

–

–

2.5-3.5

rest/bal

–

0.5

2

Mn 1.5;Si 0.5; S 0.010

Monel K 500

0.13

–

–

–

64

–

–

2.8

30

–

0.6

1

Mn 0.8

Monel R 405

0.15

–

–

–

66

–

–

–

31

–

–

1.2

Mn 1.0; S 0.04

Mechanical Properties for Forgings

Mechanical Properties of A105, A350, A694

Property	ASTM A105	ASTM A350-LF2
Tensile Strength Min, psi	70,000	70,000-95,000
Tensile Strength Min, N/mm²	485	485-655
Yield Strength Min, psi	36,000	36,000
Yield Strength Min, N/mm²	250	250
Elongation (%)	22	22
Reduction of Area (%)	30	30
Hardness, maximum	187	15/12 ft-lbs
CVN at -50℉		20/16 joules

ASTM A694 Grade	Min Yield Strength  (0.2 % Offset), in ksi [MPa]	MinTensile Strength in ksi [MPa]	Elongation in 2 in. or 50 mm, min %
A694 F42	42 [290]	60 [415]	20
A694 F46	46 [315]	60 [415]	20
A694 F48	48 [330]	62 [425]	20
A694 F50	50 [345]	64 [440]	20
A694 F52	52 [360]	66 [455]	20
A694 F56	56 [385]	68 [470]	20
A694 F60	60 [415]	75 [515]	20
A694 F65	65 [450]	77 [530]	20
A694 F70	70 [485]	82 [565]	18

Mechanical Properties of F11 Cl2, F22 Cl3, F5, F9

ELEMENT & PROPERTIES	LOW ALLOY STEEL		MEDIUM ALLOY STEEL
	F11 CL2	F22 CL3	F5	F9
TENSILE STRENGTH PSI (MPA)	70,000 (485)	75,000 (515)	70,000 (485)	85,000 (585)
YIELD STRENGTH PSI MIN	40,000 (275)	45,000 (310)	40,000 (275)	55,000 (380)
ELONGATION 2” % MIN	20	20	20	20
REDUCTION AREA % MIN	30	30	35	40
HARDNESS (HB) MAX*	143 – 207	156 – 207	143 – 217	179 – 217

Mechanical Properties of A182 F304/F316/F321

ASTM A182 Grade	Minimum Tensile Strength in MPa	Minimum Yield point in MPa	Minimum Elongation in %	Minimum Reduction of in min, %
ASTM A182 F304	515	205	30	50
ASTM A182 F304L	485	170	30	50
ASTM A182 F316	515	205	30	50
ASTM A182 F316L	485	170	30	50
ASTM A182 F321	515	205	30	50

Mechanical Properties A182 Duplex And Super Duplex

Mechanical Properties	Duplex 2205 (ASTM A182 UNS S31803 – UNS S32205)	Super Duplex ASTM A182 UNS S32750 – 32760)
Tensile Strength (in MPa)	620	770
Proof Stress 0.2% (in MPa)	450	550
A5 Elongation (in %)	25	25
Density (g.cm3)	7.805	7.81
Modulus of Elasticity (GPa)	200	205
Electrical Resistivity (Ω.m)	0.085×10-6	0.085×10-6
Thermal Conductivity (W/m.K)	19 at 100°C	17 at 100°C
Thermal Expansion (m/m.K)	13.7×10-6 to 100°C	13.5×10-6 to 200°C

Mechanical Properties of Nickel Alloy

Superalloy grade	UNS Equivalent	Yield Strength (in ksi)	Tensile Strength (in ksi)	Elongation %	Rockwell	Brinell
Nickel 200	N02200	15	55	35	–	90-120
Nickel 201	N02201	12	50	35	–	90-120
Monel 400	N04400	25	70	35	–	110-149
Monel K-500	N05500	100	140	17	–	265-346
Hastelloy B-2	N10665	51	110	40	C22	–
Hastelloy D-205	–	49	114	57	C30-39	–
Inconel 600	N06600	30	80	35	–	120-170
Inconel 800	N08800	30	75	30	–	120-184
Hastelloy C-276	N10276	60	115	50	184
Inconel 625	N06025	39	98	30	–	180
Incoloy 825	N08825	35	85	30	–	120-180
Hastelloy G-30	N06030	51	100	56	–	–
20Cb-3	N08020	35	80	30	B84-90	160

Standards of Forgings

Forging standards specify dimensions, surface finish, type of finish, marking, materials and technical specifications for forgings.

ASTM / ASME / ANSI / ASA Standards: Forging the Foundations of Quality

The American Society for Testing and Materials (ASTM), American Society of Mechanical Engineers (ASME), American National Standards Institute (ANSI), and American Standards Association (ASA) set forth industry-leading specifications for the forging process. These standards ensure consistent quality, performance, and safety across forged products.

ASTM standards, in particular, cover a wide range of materials, including carbon, alloy, stainless steel, and non-ferrous materials. ASME standards govern the design, manufacturing, and inspection of pressure vessels, boilers, and other mechanical components. ANSI and ASA standards, on the other hand, provide guidelines for developing and implementing voluntary consensus standards in various industries.

MSS Standards: Forging Ahead in Valve and Fitting Manufacturing

The Manufacturers Standardization Society (MSS) focuses on developing valves, fittings, and other pipeline components standards. By defining material specifications, pressure-temperature ratings, and dimensional requirements, MSS standards contribute to the overall safety and reliability of the fluid handling industry.

AWWA Standards: Ensuring Quality and Durability in Waterworks Components

The American Water Works Association (AWWA) sets standards for producing waterworks components, such as pipes, fittings, and valves. AWWA standards address manufacturing, installation, and testing practices, ensuring the quality and durability of forged products in the water infrastructure sector.

KS Standards: Forging Excellence in Korean Industries

Korean Standards (KS), established by the Korean Agency for Technology and Standards, provide guidelines for various industries, including forging. KS standards encompass material specifications, design requirements, and testing procedures, ensuring high-quality forged products for domestic and international markets.

DIN Standards: Forging Precision and Quality in German Engineering

Deutsches Institut für Normung (DIN), the German Institute for Standardization, sets stringent requirements for the forging industry. DIN standards cover material properties, manufacturing processes, and quality control measures, ensuring precision and quality in German-engineered forged products.

UNI Standards: Forging the Future of Italian Industry

Ente Nazionale Italiano di Unificazione (UNI) standards are developed by the Italian National Unification Agency, providing a comprehensive framework for the Italian forging industry. UNI standards address material selection, design guidelines, and manufacturing processes to ensure high-quality, reliable forged components for various applications.

European Standards: Harmonizing Forging Practices Across the Continent

European Standards (EN), developed by the European Committee for Standardization (CEN), aim to harmonize forging practices across the continent. These standards encompass material specifications, design requirements, and testing procedures, ensuring consistent quality and reliability among forged products in the European market.

BS Standards: Forging a Strong and Resilient British Industry

British Standards (BS), established by the British Standards Institution, cover many industries, including forging. BS standards provide guidelines for material selection, manufacturing processes, and testing procedures, ensuring high-quality forged products that meet the demands of the British market.

Australian Standards: Forging a Robust and Adaptable Australian Industry

Australian Standards (AS), developed by Standards Australia, set the benchmark for quality and performance in the Australian forging industry. These standards encompass material specifications, design guidelines, and manufacturing processes, ensuring the production of high-quality, reliable forged components for various applications.

GOST Standards: Forging Excellence in Russian Engineering

State Standards of the Russian Federation (GOST) establish the Russian forging industry requirements.

GOST standards address material properties, manufacturing processes, and testing methods, ensuring consistent quality and reliability in Russian-engineered forged products. These standards help maintain the high standards of the Russian market, contributing to the overall growth and development of the forging industry in the region.

SABS/SANS Standards: Forging a Strong and Resilient South African Industry

South African Bureau of Standards (SABS) and South African National Standards (SANS) are responsible for developing and maintaining standards for the South African forging industry. These standards cover material selection, manufacturing processes, and testing procedures, ensuring the production of high-quality forged products that meet the unique needs and demands of the South African market.

The Importance of Adhering to Forging Standards

Adhering to the various forging standards mentioned above is crucial for manufacturers and suppliers, as it ensures the production of high-quality, reliable, and safe forged components. These standards protect the interests of customers and end-users and contribute to the overall growth and development of the forging industry worldwide.

Forging temperature of steel

Steel type	Maximum forging temperature		Burning temperature
	(°F)	(°C)	(°F)	(°C)
1.5% carbon	1920	1049	2080	1140
1.1% carbon	1980	1082	2140	1171
0.9% carbon	2050	1121	2230	1221
0.5% carbon	2280	1249	2460	1349
0.2% carbon	2410	1321	2680	1471
3.0% nickel steel	2280	1249	2500	1371
3.0% nickel–chromium steel	2280	1249	2500	1371
5.0% nickel (case-hardening) steel	2320	1271	2640	1449
Chromium-vanadium steel	2280	1249	2460	1349
High-speed steel	2370	1299	2520	1385
Stainless steel	2340	1282	2520	1385
Austenitic chromium–nickel steel	2370	1299	2590	1420
Silico-manganese spring steel	2280	1249	2460	1350

Manufacturing process of forgings

The manufacturing process of forgings consists of several stages, including material selection, heating, forging, heat treatment, and finishing.

Raw material selection

Forging materials cover a wide range, both a variety of grades of steel and high-temperature alloys, aluminum, magnesium, titanium, copper, and other non-ferrous metals; both after processing into different sizes of bars and profiles, but also a variety of specifications of the ingot material; in addition to a large number of domestic materials suitable for our resources, but also from foreign materials. Most of the forged materials have been included in the national standards, and many of them are new materials developed, tried, and promoted. As we all know, the quality of the product is often closely related to the quality of raw materials, so forging workers must have the necessary knowledge of materials to be good at selecting the most suitable materials according to the process requirements.

Counting and downgauging

Counting and undercutting is one of the crucial aspects of improving the material utilization rate and realizing the blank’s refinement. Too much material causes waste and aggravates the wear and tear of the mold chamber and energy consumption. If you do not leave a little margin, adjusting the process and increasing the scrap rate will be more difficult. In addition, the quality of the undercut end face impacts the process and the quality of the barrel-type forgings.

Heating

The heating aims to reduce the forging deformation force and improve metal plasticity. But healing also brings problems, such as oxidation, decarburization, overheating, and overburning. Accurate initial and final forging temperature control significantly impacts product organization and performance. Flame furnace heating has the advantages of low cost and high applicability. Still, the heating time is extended, easy to produce oxidation and decarburization, and labor conditions need to be continuously improved. Electric induction heating has the advantages of rapid heating and less oxidation, but the adaptability to changes in product shape and size, and material could be better.

Calculation of deformation force

Forging and forming are produced under the action of external forces. Therefore, the correct calculation of deformation force is the basis for selecting equipment and conducting die calibration. Stress-strain analysis inside the deformed body is also indispensable for optimizing the process and controlling the organization and performance of barrel-type forgings.
There are four main methods of deformation force analysis. The principal stress method could be more rigorous. Still, it is relatively simple and intuitive and can calculate the total pressure and the stress distribution on the contact surface of the workpiece and the tool. The sliding line method is strict for plane strain problems and is more intuitive for solving stress distribution for local deformation of high parts but has a narrow application range. The upper limit method can give the overestimated load, and the upper limit element can also anticipate the change of workpiece shape during deformation. The finite element method can not only give the external load and the change of the workpiece shape but also give the internal stress-strain distribution; the disadvantage is that more computer time is needed, significantly when solving by elastic-plastic finite element, the computer capacity is more extensive and the machine time is longer. Recently there has been a trend to use a joint approach to analyze the problem, for example—rough calculation by upper limit method and fine calculation by finite element in critical areas.

Selection of equipment

Forging is based on the forgings’ material, shape, size, and process requirements to select the appropriate forging equipment. Forgings must be forged on the equipment specified in the process documents.

Select a suitable lubrication method and lubricant.

The operator should be familiar with the forging drawing and process documents before forging. The work and die used before forging must be preheated to the specified temperature using the correct method. Choose the proper lubricant according to the complexity of forgings, materials, and process requirements.
The billet should be removed from the oxide skin before and during the forging process. When forging, the starting forging temperature, the final forging temperature, the degree of deformation, and the deformation speed must be strictly controlled. During the forging operation, the process must be carried out strictly with the process rules and procedure cards. And always pay attention to the billet deformation is normal; if found fold, crack, and other defects are present, immediately use appropriate methods to remove them without affecting the quality of forgings before continuing forging.

Types of Forging Process

The forging process plays a vital role in the production of forgings. The quality of the forgings obtained (meaning shape, dimensional accuracy, mechanical property, streamlining, etc.) varies significantly from process to process, as does the type and tonnage of the equipment used. Some special performance requirements can only be solved by changing to higher-strength materials or new forging processes, such as aero-engine compressors and turbine discs. During use, the disc edges and hubs are subject to large temperature gradients (up to 300-400°C). To adapt to this working environment, dual-performance disks emerge. The dual-performance disks produced can meet the high and room temperature performance requirements through the proper arrangement of the forging process and heat treatment process. Whether the process is arranged correctly will affect the quality of forgings and the production cost; the most reasonable process should have the best quality, the lowest cost, easy operation, and can give full play to the potential of materials.

Open die forging: (type of forging process)

Open die forging usually involves using two simple shaped or flat dies that apply pressure to the material at the bottom from both sides. Open die forging is a simple hot forming process that uses standard flat, “V” shaped, convex, or concave dies on a press. The process forms an infinite array of component sizes, ranging from a few pounds to over 300 tons. The workpiece is heated to improve its plastic flow characteristics and reduce the forces required to work in the metal.
The workpiece is deformed symmetrically due to a series of strokes caused by the upper die while still on the support of the die below. The repetitive high level of compression or hammering operations on the die eventually results in the material taking the desired shape. Since the die is not entirely covered or composed of base material (hence the name open die) and provides room for free lateral movement, the process can be used to make heavier, more significant parts.
Open die forging results in tiny scrap and a final product with a better consistent grain structure and higher fatigue resistance than other forging processes. Many large industries, such as the railroad and aircraft industries, typically use the following processes to make heavy and oversized components such as rollers, cylinders, and shafts.
The open-die forging process allows the workpiece to move more freely in one or even both directions. The workpiece is usually compressed in the axial direction (where the upper die typically moves) without any lateral constraints. Transverse dimensions are created by carefully controlling the amount of axial deflection or by rotating the workpiece. Some of the most common preferred operations are grooving; distracting grief and anxiety; punching, piercing, stretching, and closing; hollow forging; and ring forging.

Stamping die forging: (type of forging process)

Known in the industry as closed-die forging, press-die forging uses a variety of dies to form the material into the desired product. However, unlike open die forging, the die is entirely closed or consists of the material at the bottom. In addition, the process requires a higher compression force to ensure that the cavities in the die are filled, and the whole desired part is formed.
Stamped die-forged parts are typically smaller than genuine die-forged parts. However, they have tighter tolerances (including near-net shape tolerances) and better surface finish quality, which contribute to lower production costs for mass production due to the reduced requirements for secondary operations for machining. The mining, automotive, and oil and gas industries often rely on this process to produce incoming parts such as flanges, fittings, and engine components.
In the simplest example, in this case, two molds are combined, and then the workpiece made of plastic is observed to deform until the expanded sides touch the walls of the mold sides. Then, a small amount of material flow is experienced from the inside of the mold to the outside of the mold impression, leading to a progressively thinner flash. The flash cools quickly and has a more excellent resistance to deformation, which helps build up pressure inside the workpiece and thus supports the flow of material into the unfilled indentation.
Generally, stamped die forgings produced on a forging machine (horizontal) (vertical die machine) are similar to forgings produced by a press or hammer. Each one is the result of forcing the metal into the cavities of the die, which deviate on the parting line.
The indentation (pattern) in the “digging tool” of the stamping operation is equivalent to a press top die or a hammer. A “clamping die” consists of an indentation corresponding to the press bottom die or hammer. Clamping dies usually consist of a fixed die and a moving die which, when in the closed position, helps to clamp the blank and hold it firmly in the desired position for the desired forging operation. These dies allow the blank transfer from one cavity to another of the multiple impression dies after each working stroke of the machine.

Cold Forging: (Type of Forging Process)

In most of the forging methods discussed above, applying heat to the base metal in one way or another, a variety of cold forging processes can still be substituted. Some examples of cold forging methods are cold heading, bending, die rolling, cold drawing, and extrusion. These processes develop various products and parts with widely varying designs.
When comparing the process to other techniques, such as hot forging, the cold forging process allows for producing parts with tighter tolerance numbers and good surface finish quality without needing heat treatment or more expensive materials. The automotive industry often uses cold forging to manufacture parts with complex or unusual geometries, such as suspension and steering, brake components, clutches, axles, gears, and pinions.

Hot forging: (type of forging process)

In hot forging, the metal is plastically deformed at a specific temperature. Then a pre-specified strain rate occurs, allowing the recrystallization process to proceed simultaneously with the deformation, thus avoiding strain hardening. To achieve this process, the high temperature of the workpiece (matching the temperature at which the metal recrystallizes) must be maintained throughout the process. Isothermal forging is also hot in which the die and the material are heated to similar temperatures.
Considering the most common cases, isothermal forging is performed on superalloys under vacuum conditions or in a highly restricted atmosphere to limit their passage through the oxidation process.

Seamless rolled ring forgings: (type of forging process)

As with other die forging processes, rolled ring forging compresses the die into the desired/desired material shape. However, instead of a flat die, the process uses a bending die, usually two opposing rolls, to form the ring-shaped part.
To seamlessly start the rolled ring forging process, the inlet is cut to the desired size and then turned down/thickened to the desired mechanical property. This ultimately results in the raw material being pushed between flat dies at its plastic deformation temperature to achieve the desired shape. The central part of the ingot center is then made into a “ring” (ring rolling). At this point, the billet is considered hot, and the middle section will be cut to move the metal radially.
Once the stamping operation is completed and a complete hole is formed in the blank, the ring is positioned to perform the rolling ring operation. It usually starts with the implied ID and OD pressures on the ring, and the same happens with the ring diameter as the press increases. A seamless rolled ring forging process is executed and completed when the desired ring diameter is obtained.
The rolled ring forging process facilitates continuous production, thereby increasing productivity and, in turn, reducing production costs. In addition, rolled ring forged parts typically have a longer life and better surface finish than other forged parts. Because of their excellent durability, they are often used in heavy equipment such as mining, aerospace engines, railroad equipment, and wind power generation.

Heat Treatment for Forgings

Stainless steel forgings, carbon steel forgings and alloy steel forgings need to be heat treated in different ways. Metal properties will have different changes after the heating, holding and cooling process, forgings are also the same. Such as stainless steel forging superior performance, it is cooled by the heating of the forging, but also one of the important parameters of the heat treatment process.

Forging in the heat treatment process, the general annealing cooling rate is the slowest, normalizing cooling rate is faster, quenching cooling rate is faster. Forgings are connected to each other and are not interrupted in the process. When heated, the workpiece is in contact with air, so oxidation often occurs. Decarburization (reduction of carbon content in the steel) has a very negative effect on the forging after heat treatment. Forgings should normally be in a controlled or protective atmosphere. Coating or packaging methods can protect the heated molten salt and vacuum. In addition, the heating temperature of the forging is one of the important process parameters in the heat treatment process, and controlling the heating temperature is the main issue to ensure the quality of heat treatment. It is usually heated above the phase change temperature to obtain high temperature tissue. Heating is one of the important processes of heat treatment. There are various methods of heating forgings and fittings, starting with the use of charcoal and coal as heat sources, followed by the use of liquid and gaseous fuels. Many manufacturers are now using electrical applications, so they are easy to control and free of environmental pollution. The use of these heat sources allows direct heating, or indirect heating of molten salts or suspended metal particles. At the same time, the performance of the forging differs from the cooling process, which mainly controls the cooling rate.

What is heat treatment of forgings

Heat treatment of forgings is a thermal cycle that consists of one or more reheating and cooling of the forging after forging, with the aim of obtaining the desired microstructure and mechanical properties in the forging. These types of forgings are rarely produced without some form of heat shield. Untreated forgings are typically relatively low carbon steel parts for non-critical applications or parts for further thermomechanical processing and subsequent heat treatment. The chemical composition of the steel, the size and shape of the product and the required properties are important factors in determining which of the following production cycles to use The equipment required for oil and gas applications can be found at Energy Products. The purpose of heat treating metals is to impart certain desired physical properties to the metal or to eliminate undesired structural conditions that may occur during the processing or fabrication of the material, such as metal fabrication. When applying any heat treatment, it is desirable to know the “prior history” or structural conditions of the material in order to specify the treatment method to produce the desired results. In the absence of information on prior treatments, a microscopic study of the structure is required to determine the correct procedure to follow.

Why do forgings need heat treatment?

Why do forgings need to be heat treated after forming? Its main purpose is to refine coarse grains, eliminate work hardening and residual stresses, reduce hardness, improve cutting properties, prevent white spots in the forging, and ensure the desired metal structure and mechanical Properties in preparation for the final heat treatment. Now let’s talk about several forms of heat treatment. Commonly used heat treatments for forgings are spheroidizing, normalizing, annealing, quenching and tempering. They involve heating the material to a specific predetermined temperature using a fire tube boiler, “soaking” or maintaining it at that temperature, and cooling it at a specified rate in air, liquid or retarding medium. The above treatments can be briefly defined as follows.

Spheroidization – The prolonged heating of an iron-based alloy at a temperature slightly below the critical temperature range, followed by relatively slow cooling, usually in air. Smaller objects of high-carbon steel are more quickly spheroidized by continuous heating at temperatures within and slightly below the critical temperature range. The purpose of this heat treatment is to produce spherical carbides.

Normalizing – Heating an iron-based alloy to about 50°C above the critical temperature range and then cooling it in air to below that range. Its purpose is to leave the metal structure in a normal condition by removing all internal strains and stresses that are imparted to the metal during certain machining operations. Plasma cutting equipment is used when the metal needs to be resized or deformed. It is used to heat forgings above the transformation temperature to form a single austenitic structure, after a period of uniform temperature stabilization, and after air cooling in a blast furnace, with the main purpose of refining the grain. The standardized temperature range is usually between 760 and 950 degrees Celsius, depending on the phase transition points of the different component contents. As a rule, the lower the carbon and alloy content, the higher the normalizing temperature and the lower the normalizing.

Annealing – is a comprehensive term applied to heat treatments that can be used to relieve stress; induce softness; alter ductility, toughness, electrical, magnetic or other physical properties, refine crystal structure; remove gases; or produce microstructures. The treatment temperature and cooling rate depend on the object to be treated and the composition of the material being heat treated. Hardening – is the heating and quenching of certain iron-based alloys from temperatures within or above the critical temperature range. The heating temperature and the length of time at this temperature, or “homogenizing period”, depend on the composition of the material. The quenching medium used may depend on the composition, the desired hardness and the complexity of the design.

Tempering – is the reheating of an iron-based alloy after it has been hardened to a temperature below the critical temperature range and then cooled at any desired cooling rate. The purpose of tempering is to remove strain and reduce hardness and brittleness. The main purpose of tempering is to expand the hydrogen. It also stabilizes the organization after phase transformation, eliminates phase transformation stresses, reduces hardness, and makes forgings easy to machine without deformation. There are three tempering temperatures: high-temperature tempering, medium-temperature tempering and low-temperature tempering. Among them, the high-temperature tempering temperature is 500-600, medium-temperature tempering temperature is 350-490, low-temperature tempering temperature is 150-250. The cooling rate after tempering should be slow enough to prevent whitening due to excessive transient stresses during cooling and to minimize residual stresses in the forgings.

Cooling of forgings

The cooling method specified in the forging process specification shall be followed. Heat treatment after forging shall be carried out according to relevant process documents. It can be carried out according to the process procedures of the manufacturer or according to the process requirements proposed by the user. Still, it must be noted when signing the contract. For Class I and II forgings, special process instructions shall be provided when necessary, and initial production process and tooling tests shall be conducted. After verification, they can be put into production. Quality archives shall be established for Class I and II forgings according to the forging drawing number.

Machining of Forgings

In the process of forging processing, each processing step and heat treatment step can produce processing errors and stresses to varying degrees, so it is necessary to divide the processing stages. Forging processing is divided into the following three stages.
(1) Rough machining stage

• 1) Blank processing Blank preparation, forging, and normalizing.
• 2) Rough machining involves sawing off excess parts, milling end faces, drilling center holes, and roughening the outer circle.

(2) Semi-finishing stage

• 1) Heat treatment before semi-finishing is generally used for 45 steel to achieve 220 to 240 HBS through quenching and tempering.
• 2) Semi-finished turning process cone surface (positioning cone hole), Semi-finished turning outer circular end surface, drilling deep holes, etc.

(3) Finishing stage

• 1) Heat treatment before finishing Local high-frequency quenching.
• 2) Before finishing, various processes such as rough grinding of positioning cone surface, rough grinding of the outer circle, milling of keyway and spline groove, and thread turning are performed.
• 3) Finish machining and grinding the outer circle and inner and outer conical surfaces to ensure the accuracy of the most critical surface of the forging.

(4) Arrangement of processing sequence and determination of working procedures
Several options for shaft forgings with hollow and inner cone characteristics are available when considering the processing sequence of main surfaces, such as bearing journals, general journals, and inner cones.

• ① Rough machining of outer surface; Drilling deep holes; Surface finishing; Rough machining of tapered holes; Finish machining of tapered holes;
• ② Rough machining of outer surface; Drilling deep holes; Rough machining of tapered holes; Finish machining of tapered holes; Surface finishing;
• ③ Rough machining of outer surface; Drilling deep holes; Rough machining of tapered holes; Surface finishing; Finish machining of tapered holes.

For the machining sequence of CA6140 lathe forgings, the following analysis and comparison can be made:
The first scheme: During the rough machining of tapered holes, the precision and roughness of the outer circular surface will be damaged by using the finished outer circular surface as the precision reference surface, so this scheme is unsuitable.
The second solution: When finishing the outer circular surface, a conical plug should also be inserted, which will damage the accuracy of the tapered hole. In addition, there will inevitably be processing errors when machining a tapered hole (the grinding conditions of the tapered hole are worse than those of the cylindrical grinding, coupled with the error of the cone plugs itself, which can cause different shafts on the cylindrical surface and the inner conical surface, so this scheme is also not suitable.
The third scheme: When finishing the tapered hole, although it is also necessary to use the finished outer circular surface as the precision reference surface; However, due to the small machining allowance for finishing the conical surface, the grinding force is not significant; At the same time, the finishing of the tapered hole is already in the final stage of shaft processing, and the impact on the accuracy of the outer circular surface is not significant; In addition, the processing sequence of this scheme can use the outer circular surface and the tapered hole as mutual benchmarks, which can be used alternately to improve coaxially gradually.
After this comparison, it can be seen that for shaft forgings such as CA6140 forgings, the third scheme is the best processing sequence.
Through the analysis and comparison of the schemes, it can also be seen that the sequential processing sequence of each surface of shaft forgings is primarily related to the conversion of positioning benchmarks. When the coarse and fine benchmarks for machining parts are selected, the machining sequence can be roughly determined. Because the positioning reference plane is always processed first at the beginning of each stage, the previous process must prepare the positioning reference for the subsequent process. For example, in the CA6140 forging process, the end face is milled, and the center hole is punched at the beginning. This is to prepare a positioning reference for the outer circle of rough and semi-precision turning; Semi-finished turning of the outer circle provides a positioning reference for deep hole machining; Semi-finished turning of the outer circle also prepares a positioning reference for the processing of the front and rear tapered holes. In turn, the front and rear tapered holes are fitted with tapered plugs to provide a positioning reference for subsequent semi-finishing and finishing of the outer circle; The positioning reference for the final grinding of the tapered hole is the surface of the shaft neck polished in the previous process.
(5) The determination of processes should be carried out by the processing sequence, and two principles should be grasped:
The positioning reference plane in the process should be arranged for processing before the process. For example, deep hole processing is arranged after rough turning of the outer circular surface to have a more accurate journal as the positioning reference plane to ensure uniform wall thickness during deep hole processing.
The processing of each surface should be separated from coarse to fine, starting from coarse to fine, and repeated processing to improve its accuracy and roughness gradually. The finishing of the main surfaces should be arranged last.
“Heat treatment processes, such as annealing and normalizing, arranged to improve the microstructure and processing properties of metals should generally be arranged before mechanical processing.”.
The heat treatment procedures arranged to improve the mechanical properties of shaft forgings and eliminate internal stress, such as quenching and tempering, aging treatment, etc., should generally be arranged after rough machining and finishing.

Final inspection of forgings

Final inspection of die forgings shall be carried out by relevant regulations such as forging drawings and contracts. Final inspection of free forging forgings shall be carried out by relevant regulations such as forging drawings and contracts. Inspection marks (labels) or other marks can be placed on the specified forging parts.
The inspector inspects each process, and the products that pass the inspection shall be transferred to the process with the inspector’s signature. The unqualified products shall be executed according to the company’s “Nonconforming Product Control Procedure” procedure document.
Dimensional inspection of forgings
Use general or special tools to measure, scribe, test process, and other methods to comprehensively inspect the shape and size of forgings and record the actual situation
result.
Surface condition inspection
Inspect the surface roughness, surface defects, and appearance status of forgings according to the technical standards for forgings, and if necessary, inspect
Check for metallurgical defects such as alloying element depletion and contamination on the surface.
Internal quality inspection
Inspect the mechanical properties, macrostructure, microstructure, etc., of forgings according to the technical standards for forgings (including periodic inspection items)
Additional inspection items can be added if necessary.
Ultrasonic examination
After the cooling, the temperature of the forging shall be reduced to about 20 ℃ for ultrasonic flaw detection to meet national standards I, II, III, and other standards, as well as inspection of surface defects.
Mechanical performance test
To meet customer requirements, the mechanical properties of forgings must be tested, mainly yield, tensile, impact, and other tests. The leading testing equipment of the enterprise includes 1 universal mechanical property testing machine, 1 impact testing machine, 1 continuous steel bar dotting machine, 1 ultrasonic flaw detector, 1 magnetic particle flaw detector, 2 thermometers, 1 electric double blade broaching machine, 1 impact cryometer, 1 metallographic microscope, 1 metallographic pre grinding machine, 1 metallographic cutting machine, 2 Brinell hardness meters, etc., which can meet the needs of conventional testing of various types of forgings.
Carry out a final inspection on the finished forgings to ensure that the appearance of the forgings is flat and free of defects such as cracks, that the dimensions are within the requirements of the drawings, and make records.

Warehousing

After quality testing, the finished forgings are packaged and sent to the finished product warehouse for shipment.

Inspection before packaging

Full-time inspectors shall strictly inspect the size, surface quality, and identification of the machined product by the drawings, then retest the product to prevent confusion.

Packaging process

• ① Typing: Typing shall be carried out according to the typing notice in the Production Task List. After the first article self-inspection, full-time packaging inspectors shall conduct the first article inspection. After passing the inspection, batch typing shall be carried out. During the process, a spot check shall be conducted on the clarity of the handwriting to ensure that the typing is clear and tidy.
• ② Rust prevention treatment: The treatment (oil coating, painting, etc.) shall be carried out according to customer requirements. Operators shall conduct self-inspection as required. Full-time packaging inspectors shall conduct the first article, routine, and process inspection on the rust prevention treatment and surface quality as required. If qualified, they shall enter the packaging process. Otherwise, they shall be reworked.

Control of nonconforming products

The inspector shall identify and isolate the nonconforming products, fill in the Nonconformity Handling Form, and submit it to authorized personnel for handling. The Nonconformity Control Procedure shall be strictly followed to ensure that the non-conforming products are identified and controlled and to prevent unintended use or delivery.

Welding Repair Requirements for Forgings

Welding is a popular and cost-effective way to repair a forging. However, welders must adhere to certain quality control guidelines if they want their repairs to be effective and last as long as possible. Forgings are used in many industries, including oil and gas pipelines. When they break or crack due to extreme pressure or temperature changes, they can cause major problems for an entire facility. Forging repair is important because it ensures that the integrity of the entire system remains intact—and your repair must meet certain requirements before you start working on it!

Cracking

Cracks in a weld are a sign of low quality workmanship. They can lead to leaks, which can cause corrosion. A crack is also an indication of lack of control over the welding process, and can lead to other defects such as porosity and slag inclusions that may weaken the weld joint. Cracks should be repaired using Tack Welding techniques, which involves a very small diameter weld bead (1/8″ or smaller). The weld bead should be smooth and uniform with no gaps between them; if it is not perfectly round then it means that you did not control your puddle well enough during the welding process.

Surface Discoloration and Appearance

Welding the forging surface can cause discoloration and appearance issues. Discoloration and appearance issues may be caused by overheating, flux and impurities in the metal, lack of cleaning before welding, or even the type of metal being welded.

Welding Processes

Welding processes are the ways in which a weld is created. Three of the most common welding processes are gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), and flux cored arc welding (FCAW). When repairing a forging, it’s important to know that each process requires a different amount of heat to reach its optimal temperature. For example, FCAW requires higher temperatures than GMAW or GTAW. This can be problematic if you don’t have an adequate way to keep these parts heated during your repair work.

Welders should adhere to quality control guidelines when repairing forgings.

When checking the weld, you should examine the surface of your weld. It should be smooth to the touch and without any cracks or holes. If there are any cracks or holes in your weld, you will need to re-weld that area until it is sound. You must also check that your forging has been cleaned before welding it back into place by using an abrasive cloth and/or wire brush. Any dirt or oil on the forging could lead to corrosion over time, which will weaken its structural integrity and cause leaks (if it hasn’t already).

Applications of Forgings

Forgings are a key component in the construction of industrial and commercial facilities. Forgings can be used for many different applications, such as connecting two pipes and valves, which is what makes them so important.

Forgings in petrochemical plants

Forgings are used as a way to connect pipes and tubes in many industrial applications, including:

• Connecting pipes to other forgings;
• Connecting valves to pipes or tubes;
• Connecting pumps to their respective piping.

The Importance of Forging Design in the Chemical Industry

The forging is the most important part of the piping system. It must be designed to handle the pressure of the system and it must be designed to handle the temperature of the system. To ensure that the forging is designed correctly, it should be hydrostatically tested so that it can withstand any pressure that may occur within the chemical plant or refinery.

Forgings in oil and gas production

Forgings are used in oil and gas production. They are used in pipelines, valves, pumps, and other components connected to pipelines. Forgings have several important functions. To ensure a tight seal on the pipe or fitting to which they are connected. To allow easy installation with minimal effort; forgings can be installed quickly by first screwing them into place and then tightening them for added strength. So that they can be easily removed when necessary (for example, when replacing a damaged part of a pipe or piece of equipment).

How do I choose the right forging for the heavy industry?

Forgings are essential for strong connections and are used in the oil and gas industry. They ensure that pipe joints are secure and prevent corrosion. If you are working on a project that requires forgings, it is important to choose the right type of forging for the job. There are different types of forgings available for heavy industrial applications. Butt-weld forgings: This type of butt-weld forging is typically used where high pressure or high-temperature requirements need to be met. The butt-weld type has no flat surface; instead, it has two discrete edges that can be joined using bolts or screws through holes drilled into each side of the material, with gaskets sandwiched in between to tightly seal against leaks or other unwanted migration through the area, while still allowing for easy disassembly if necessary when maintenance is required later.” We can provide you with the best forging for any application. We will help you find the type of forging that meets the requirements for size, material, and connection method.

How to purchase the correct industrial forging?

When it comes to selecting an industrial forging, there are a number of factors you should take into account. One aspect is the application: what type of pressure, temperature and material are you working with? You should also consider the size and shape of your connection, as well as how much weight it’s supporting. After deciding on these things, you’ll be able to find the best industrial forging for your needs!

Consider the application.

When you’re looking for a forging, the first thing to consider is the application. What kind of equipment will you be connecting? What pressures will it be subjected to? And what type of material are you working with?
Next, think about pressure class. The pressure class number indicates how much pressure can build up inside a connection before it fails and breaks apart. The higher the number, the greater capacity there is for holding higher pressures without breaking—a must-have when considering industrial applications like hydraulic cylinders or pumps that rely on metal forgings to function correctly (and safely).
Then there’s material: Stainless steel has become a popular choice because it provides superior corrosion resistance and doesn’t require sealing gaskets around each connection point (which saves time). However, this material can be costlier than other options such as carbon steel or aluminum alloy when considering both initial installation costs and maintenance/replacement costs down the line due to its increased lifespan in harsh environments where other materials may fail sooner than expected due solely upon their exposed nature within those same environments.”

Examine the size of the connection.

The size of the forging should be based on the size of your pipe. It should be large enough to accommodate the pipe and gasket, but not so large that it’s difficult to install or remove.
Check the material of the forging for corrosion resistance.
The material of the forging is an important consideration, as it determines how well it will resist corrosion. Stainless steel is more resistant to corrosion than carbon steel, but it isn’t indestructible. Some grades of stainless steel are more corrosion-resistant than others, with 304 being the most common material used in industrial forgings. If you need a forging that’s more corrosion-resistant than 304 stainless steel, 316 is your best choice. It’s used in chemical and petrochemical applications because it has higher corrosion resistance than other types of stainless steel, making it ideal for harsh environments where chemicals are present.

Choose an affordable forging necessary to your application.

Make sure to choose an affordable forging necessary to your application. To ensure that you can afford the forging, conduct research into the prices of different types of industrial forgings and how much each costs. Industrial forgings are not cheap, but they should be affordable enough for you to purchase one without breaking the bank.

Confirm the forging’s pressure class.

Pressure class is the maximum pressure the forging can withstand. The class is usually indicated on the forging. If you’re having trouble locating this information, refer to your handbook or contact your supplier for assistance.

• Class 150: 1,500 pounds per square inch (psi).
• Class 300: 3,000 psi.
• Class 600: 6,000 psi.

The higher the pressure rating, the more rigorous it is to manufacture a high-quality product that can withstand these pressures without leaking or breaking down under strain.  

How to select forgings manufacturer

When selecting a forging manufacturer, several factors must be considered, such as the quality of their products, the availability of the type of forging required, and the price. You may also want to consider the manufacturer’s reputation and experience in the industry. The following are some of the steps in selecting a forging manufacturer.

• Determine forging requirements: Before you begin your search for a forging manufacturer, it is important to have a clear understanding of the type, size, material, and any other specific requirements of the required forging. This will help you narrow down your choices and make it easier to find a manufacturer that can meet your needs.
• Research potential manufacturers: Once you have a clear understanding of your forging requirements, you can begin researching potential manufacturers. You can look for manufacturers that specialize in the type of forging you need and check out their websites and online reviews to learn more about their products and services.
• Request a quote: Once you have a shortlist of potential manufacturers, you can contact them and request a quote for the forgings you need. This will give you an idea of the price and availability of the forging you need.
• Consider other factors: In addition to pricing and availability, other factors should be considered when selecting a forging manufacturer, such as the quality of their products, their experience and reputation in the industry, and their customer service.
• Make a decision: After considering all relevant factors, you can make a decision and select a forging manufacturer. It is important to choose a manufacturer that can provide the required forgings at competitive prices and has a proven track record of producing high-quality products.

Where to find forging manufacturer?

If you are looking for a forging manufacturer, there are many ways to find one. Here are some suggestions. Search online for manufacturers in your industry. For example, if you are looking for a forging manufacturer, you can search for “forging manufacturer” and see what comes up.

• Look for manufacturer directories, which lists manufacturers by industry.
• Ask other businesses in your industry for suggestions. They may know of good manufacturers they can recommend.
• Attend industry-related trade shows and conferences. These events are a great way to meet with manufacturers and learn about the latest products and services they offer.
• Contact your local Chamber of Commerce or Small Business Administration office. They may be able to provide you with information about manufacturers in your area.

It is important to research and carefully evaluate potential manufacturers before working with them. Make sure they have a good reputation and can provide the product or service you are looking for.