FORGE February 2012

The International Journal of Forging Business & Technology www.FORGEmag.com

LEHIGH HEAVY FORGE: Long History, Large Parts FORGExpo 2011 Review Distortion in Rolled Rings Ten Years of the “New” Euroforge TECH Spotlights

FORGE 5-Year Feature Article Index

February 2012

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CONTENTS F E AT U R E S

Vol. 4, No. 1 • February 2012

FORGExpo 2011: A Global Forging Industry First The global forging industry experienced a first on Nov. 10, 2011, when this publication hosted FORGExpo 2011: An International Virtual Event. The event featured a lineup of speakers, exhibitors and social networking options in an online graphic interface.

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Distortion in Rolled and Heat-Treated Rings The rolling and thermal treatment of forged rings sometimes leaves residual stresses that cause dimensional distortion. Corrective measures are often based on trial-and-error techniques, but ongoing research seeks to base corrective actions on the laws of physics.

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Ten Years of the “New” Euroforge

COVER STORY

Euroforge is the umbrella organization of the European national associations for the forging industry. Negotiations between these national associations resulted in the founding of the “New” Euroforge in Paris on Nov. 10, 2000.

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Lehigh Heavy Forge: Long History, Large Parts Located in Bethlehem, Pa., this company claims to be the sole remaining super-heavy open-die forging company in the Western Hemisphere. More than a century old, the company’s historic facilities were the birthplace of the modern U.S. defense industry.

FORGE (ISSN 1949-8438) is published 4 times annually, February, May, August and November by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248)362-3700, Fax: (248)362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2012, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address To FORGE, P.O.BOX 2147, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248)244-6499 or [email protected].

18 DEPARTMENTS & COLUMNS Editor’s Page .......................................................6 FIA’s Public Policy Watch ......................................7 News ..................................................................8 FORGE Feature Article Index .............................20 TECH Spotlights .................................................23 Products ............................................................36 Classified ..........................................................39 Ad Index ...........................................................42 On the Cover: At Lehigh Heavy Forge, a large shell is removed from a heat-treating furnace for quenching.

February 2012

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EDITOR'S PAGE Pittsburgh Office Manor Oak One, Suite 450 1910 Cochran Road, Pittsburgh, PA 15220 Phone: (412) 531-3370 • Fax: (412) 531-3375 Corporate Office BNP Media • 2401 W. Big Beaver Road Suite 700, Troy, MI 48084 • www.bnpmedia.com

Contemptible Congress DEAN M. PETERS, EDITOR

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ould you take a job in the public sector that offered the following for an entrylevel employee? • $174,000 in annual compensation An inflation-adjusted pension plan that was two or three times more generous than those offered to similarly paid private-sector employees A health-care plan that included vision and dental benefits, health savings accounts, life and long-term-care insurance, and free outpatient treatment (not extended to family members) at military hospitals An annual office budget ranging from about $1 million to $4 million per year to pay for staff, with a separate office furniture budget on top of that A liberal travel budget, though less so than it was several years ago A full contingent of paid legal holidays, plus a week off for President’s Day and Memorial Day and frequent recesses regardless of whether your work was done or not Free parking at the office and at local major airports for when you travel An assortment of other privileges and perks far too numerous to mention here

You probably know by now that I am speaking of members of Congress. Given this level of compensation and comparing it to U.S. Census data, it can be calculated that a typical member of Congress earns (if you’ll pardon the great leap of faith here) more than 97% of his or her constituents. Now, those of us with a reasonable work ethic might expect someone receiving such a compensation package to put their all into their work – each and every day. And so I come to my point. Last summer, Congress and the Obama Administration agreed to a budgetceiling deal, enacted by Congress as the Budget Control Act of 2011. This law created a Joint Select Committee on Deficit Reduction – the so-called “Super Committee,” a gross misnomer if ever I’ve heard one. The only job of this committee was to formulate a list of budget cuts that would reduce this country’s budget deficit by $1.2 trillion during the next 10 years. Further, the Committee’s work was not to be hampered by the introduction of amendments – its work was to be subject to an up-or-down vote – or the threat of filibuster in the Senate. The Super Committee’s plan was to be voted on in committee last Nov. 23, but, alas, the Committee announced on Nov. 21 that it would not meet its deadline. After last summer’s budget-ceiling debacle, one would expect the Congressional Super Committee to have bent over backwards to get the job done in a timely manner and show the American people their Congress really was working. Instead, they again lived down to everyone’s expectation and failed miserably to meet the mandate of a Congressional act. If a private citizen failed to abide by an Act of Congress, contempt proceedings would probably be the result. I try to resist the temptation to toss all of Congress into the category of overpaid and underworked elitist politicians. There may be some members who are really trying to earn their paychecks and provide leadership and inspiration to the American electorate, but the only name I can come up with that meets that bill is Gabrielle Giffords.

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Februar y 2012

Doug Glenn Publisher [email protected] • 412-306-4351 Reed Miller Editorial Director [email protected] • 412-306-4360 EDITORIAL & PRODUCTION Dean M. Peters Editor [email protected] • 216-570-4537 Bill Mayer Associate Editor [email protected] • 412-306-4350 Beth McClelland Production Manager [email protected] • 412-306-4354 Brent Miller Art Director [email protected] • 412-306-4356 AUDIENCE DEVELOPMENT Christina Gietzen Audience Development Specialist Alison Illes Multimedia Specialist For subscription information or service, please contact Customer Service at: Ph: 847-763-9534 or Fx: 847-763-9538 LIST RENTAL Postal contact: Kevin Collopy Sr. Account Manager, Ph: 845-731-2684; Toll Free: 800-223-2194 x684; [email protected] E-mail contact: Michael Costantino Sr. Account Mgr.. Ph: 845-731-2748; Toll Free: 800-223-2194 x748; [email protected] Single Copy Sales: Ann Kalb Ph: 248-244-6499; Fax: 248-244-2925; kalbr@ bnpmedia.com SALES REPRESENTATIVES Kathy Pisano Advertising Director (412) 306-4357, Fax (412) 531-3375 [email protected] Larry Pullman Eastern & Western Coast Sales Manager Toll free 1-888-494-8480 or (678) 494-8480 Fax (888) 494-8481, [email protected] Steve Roth Midwest Sales Manager (520) 742-0175, Fax (847) 256-3042 [email protected] Becky McClelland Classified Advertising Mgr. [email protected] • 412-306-4355 Patrick Connolly European Sales (44) 1-702-477341; Fax: (44) 1-702-477559 [email protected] Mr. Arlen LUO Newsteel Media, China Tel: 0086-10-8857-9899; Fax: 0086-10-8216-0061 [email protected]

Publishing: Corporate Strategy: Information Technology: Production: Finance: Creative: Directories: Human Resources: Events: Clear Seas Research:

John R. Schrei Rita M. Foumia Scott Krywko Vincent M. Miconi Lisa L. Paulus Michael T. Powell Nikki Smith Marlene J. Witthoft Scott Wolters Beth A. Surowiec

FIA’s Public Policy Watch Laurin M. Baker, Founder & President + The Laurin Baker Group, LLC Washington, D.C. + FIA Washington Representatives 202-393-8525 + [email protected]

Streamlining Regulations on the Export of Aerospace Forgings Laurin Baker A periodic report about the Forging Industry Association’s (FIA) efforts to inform members of Congress and government regulators about issues of concern to the forging industry

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ne of the areas of government policy and regulation that affects manufacturers such as forgers is export controls on certain defense articles and related components and parts. Over the years, the regulatory regimes governing such exports have grown increasingly complex and confusing, with overlapping jurisdictions and inconsistent applications. U.S. manufacturers and their trade associations, including FIA, have long argued that this complexity has resulted in lost export opportunities for U.S. manufacturers. A major effort to revise and streamline these regulations started under the Bush Administration and continued under President Obama with the goal of ensuring that items are controlled when appropriate, but only to the level required to ensure U.S. security. FIA has been monitoring this effort and recently provided comments to both the U.S. Department of Commerce and the U. S. Department of State on proposed revisions to regulations governing the export of aircraft and related items. Under today’s export-control regulatory scheme, aerospace forgings, while rarely “specially designed” for military aircraft, are subject to the International Traffic in Arms Regulations (ITAR) because they appear on the U.S. Munitions List (USML), which is administered by the U.S. Department of State. (“Specially designed” is a “term of art” used in export-control regulations having to do with form, fit and function of the part/component as it relates to the defense item in question.) Other aerospace forgings not subject to ITAR regulations (which at a minimum require costly registrations and licenses) may still be subject to control under the Export Administration Regulations (EAR), which is administered by the U.S. Department of Commerce. Determining whether a forging is subject to export controls, and which controls apply, is a challenging task at best, and the penalties for mistakes can be severe, including loss of export privileges. In general, the Administration’s proposed revisions to Category VIII of the USML (aircraft and components thereof) are intended to describe more precisely which military aircraft and related defense articles warrant control by the USML; which articles are subject to the EAR; and which articles require little to no export controls consistent with international obligations. On Dec. 22, 2011, FIA filed comments stating its support for

this general approach, under which only those forgings that are “specially designed” for a specific list of U.S.-origin aircraft that have low observable features or characteristics (so-called stealth aircraft designed to avoid detection by radar) should be subject to continued control on the USML. All other forgings “specially designed” for a military aircraft should be subject to the jurisdiction of the U.S. Department of Commerce consistent with the Wassenaar Arrangement Munitions List (WAML), an international agreement supported by the U.S. Under the WAML, forgings and castings are subject to a control regime that applies to unfinished products only when they are “identifiable by material composition, geometry or function.” FIA argues that is a rare occurrence. Because many forgings used in aircraft production are shipped to the customer in “raw” form, requiring substantial additional machining and manufacturing processes, FIA believes that many aircraft forgings are not “identifiable by material composition, geometry or function” when they are shipped to the customer. Therefore, FIA hopes that when the rules are finalized, most aerospace forgings currently subject to ITAR regulations would be under the jurisdiction of the Department of Commerce’s “dual use” export-control regulations – a significant reduction in regulatory burden and red tape. As part of the finalization of the proposed rules, all public comments will be reviewed, and the Administration will seek Congressional approval for removal of items from the USML. FIA will continue to monitor this effort to ensure that the concerns of forgers are taken into account.

Februar y 2012

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NEWS

Raymond to Acquire Trinity India

Sanghvi Forging to Commission New Plant

Raymond Ltd., a Mumbai-based conglomerate known primarily for its textiles, is acquiring a majority stake in Trinity India Ltd., a manufacturer of forged auto components. Pune-based Trinity is being acquired through Raymond’s Ring Plus Aqua subsidiary, which manufactures ring gears, flex assemblies and precision sheet-metal components. Trinity India, which has five manufacturing facilities in the country, exports more than 60% of its total sales. Its customers include Tata Motors, Maruti Suzuki, Ford India, Force Motors, Turbogears and Iljin Auto Motors, among others.

India’s Sanghvi Forging and Engineering Ltd. (SFEL), a producer of forgings for the non-automotive sector, is changing its product mix to more closely focus on low-volume, higher-margin and larger products used in the aerospace, nuclear power generation, oil and gas, and defense industries. As part of this shift, the company has commissioned a new plant at Vadodara, major equipment for which is expected by February 2012. The new facility will have an annual capacity of 15,000 tons.

AAM Expands Joint Venture with China’s JAC Group On Dec. 1, Detroit-based American Axle & Manufacturing Holdings Inc. (AAM) announced the expansion of its existing joint venture with China’s Hefei Automobile Axle Co. (HAAC), a subsidiary of the JAC Group (Anhui Jianghuai Automotive Group Co.). The expansion will include all of HAAC’s light commercial axle business. The existing joint venture, Hefei AAM Automotive Driveline & Chassis System Co., supplies rear beam axles, reardrive modules, power transfer units and suspension corners for passenger cars, SUVs and other vehicles made in China. The expanded joint venture will supply front and rear beam axles to several leading Chinese light-truck manufacturers.

SMS Meer to Supply New Press Line to Dongfeng Nissan in China The Dongfeng Nissan Passenger Vehicle Company (Guangzhou, China), which recently unveiled its Venucia auto brand in China, placed an order with SMS Meer for the supply of a wedge press with forging roll intended for the auto company’s new forging works in Guangzhou. The wedge press is an AKP 2500 with a forging force of 25 MN. The ARWS 1 forging roll pre-forms the material to be forged. Dongfeng Nissan will produce rods only for its own car production at the plant. Commissioning of the new forging line is scheduled for the beginning of 2013.

SIFCO Industries Acquires Quality Aluminum Forge SIFCO Industries Inc. of Cleveland, Ohio, acquired the business and related assets of GEL industries Inc. doing business as Quality Aluminum Forge (QAF), an aerospace component supplier located in Orange, Calif. QAF is principally known as a supplier of precision-forged and machined aerospace components for use on commercial and military aircraft. The transaction, which includes essentially all of the operating assets and liabilities of QAF, closed on Oct. 28. The acquisition enhances SIFCO’s product offering by adding a new metal capability and increasing the company’s finishmachining capability. 8

February 2012

A. Finkl & Sons Celebrates First Heat of Steel-Forging Furnace A. Finkl & Sons, with the help of Great Lakes Mechanical Services of Crete, Ill., and SMS Siemag, celebrated the first heat of a new steel-forging furnace in over 100 years on Chicago’s south side. Designed by SMS, the 90-ton electric arc furnace was assembled over the course of 16 months by Great Lakes Mechanical’s staff in conjunction with Finkl technicians. Building the new furnace meant assembly from the ground up, including the hydraulic system and the furnace casing itself. Located within Finkl’s new facility in Chicago and creating a high-quality steel product used in forging dies, plastic molds, die casting tools, custom open-dies and other applications, the furnace now runs seven days a week, 10 hours a day.

Bharat Forge-Alstom Venture to Secure Financing The joint venture between French power company Alstom and Bharat Forge of India reported in this column in December 2009 seems to be on track. A source close to the venture has reported that the joint venture plans to sign a loan agreement next month for $271 million. At least seven financial institutions are reportedly involved in the 12-year loan deal led by Axis Bank and ICICI Bank, both Indian institutions.

PRV Metals Acquires TechSpec PRV Metals, a portfolio company of Denver, Colo.-based Platte River Ventures, acquired the stock of TechSpec Inc. (TSI). TSI, of Derry, Pa., provides specialty rolled and forged titanium products to the commercial aerospace, defense, medical, energy and industrial sectors. TSI’s capabilities include hot rolling, forging, conditioning, heat treating and machining of titanium into round bar. This is the second recent acquisition for PRV Metals, which also acquired California-based Sierra Alloys Company last November.

CALENDAR May 5-8 – FIA Annual Meeting of Members, Palm Beach, Fla. www.forging.org May 28-31 – 2012 OpenForge, Zhengzhou Henan, China openforge.chinaforge.org.cn

FORGExpo 2011:

Global Forging Industry First Dean M. Peters, editor The global forging industry experienced a first on Nov. 10, 2011, when this publication hosted “FORGExpo 2011: An International Virtual Event,” the forging industry’s first virtual trade exhibition. The event featured a lineup of speakers, exhibitors and social networking options in an online graphic interface at which papers were presented and online Q&A sessions were held in real time.

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nyone who pre-registered for the event at www. n FORGExpo.com and followed the prompts to attend F tthe show in real time was treated to a virtual event ccomplete with lobby, auditorium, exhibitor displays, technical h i l papers, line Q&A sessions, a networking lounge and private chat rooms – all from the comfort of their own offices, homes or any other place they chose to open their laptops and log in. The graphic interface offered the opportunity for attendees to chat with industry suppliers; attend the technical program and hear speakers while simultaneously viewing their Powerpoint slides; collect product and company information in the form of brochures, videos, white papers and chat (live) within exhibitors’ booths, each of which was manned in real time by company personnel. And, as often happens at live exhibitions, prizes were given away. We at FORGE magazine were also new to such an event and knew not what to expect, but by all accounts the virtual format went off smoothly. The event logged 463 total registrants who, once they logged in, found themselves in a virtual lobby listening to a welcoming audio clip and a brief description of how to navigate the show floor and its features.

International (ATI). His presentation, called “Feast or Famine? Will the Global Forging Industry Survive?” examined the forging industry’s history, its current status and key markets, and the competitive challenges it faces in the future. Carola Sekreter, technical director of the Forging Industry Association (FIA), followed the keynote talk with her paper, “Research Activities Within the North American Forging Industry.” This talk discussed the various research projects coordinated through FIA and the Forging Industry Educational and Research Foundation (FIERF). These projects, usually in partnership with industry and/or academic institutions affiliated with the forging industry, attempt to identify and solve problems encountered in forge shops. Dr. Chester Van Tyne, “FIERF Named Professor” at the Colorado School of Mines, closed the program with a technical paper that reviewed an actual collaboration between academia and industry. The paper was entitled “Comparison of Forging Processes for 304L Stainless Steel: An Example of an Industry/University Cooperative Research Project.” During the presentations, attendees were invited to type in questions, which were answered in real time during the show.

Speaker Program One keynote speaker and two other presenters made up the technical program for the event. The keynoter was Jon Tirpak, executive director of Forging Defense Manufacturing Consortium (FDMC) and forging portfolio manager for Advanced Technology

Initial entry to FORGExpo 2011 was through the event lobby.

On the Expo “Floor” Upon entering the expo “floor” one is greeted with a graphic that simulates an entry lobby and registration area, complete with a low level of ambient noise. Attendees to the show are given a

Attendees could listen to the technical papers and view the presentations in the FORGExpo audiorium. February 2012

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Attendees could scroll (but not stroll) from booth to booth to visit exhibitors in the exhibit hall.

The networking lounge was where attendees went to “unwind” and have a private or group chat with other colleagues.

virtual briefcase, which they can fill with information from the various exhibitor booths they visit. Downloaded pieces of information, called collateral, are placed inside the briefcase, which serves much like the shopping cart seen at some online shopping sites. Collateral information can take the form of product brochures, company brochures, video clips, photographs, technical papers and other media items. From the entry lobby, attendees could head to the auditorium, where the technical program for the day was presented, as reviewed in the previous section. Also from the lobby, access to the exhibit floor was only a mouse click away. Once there, an attendee could scroll from booth to booth, entering only those that were of interest. Each booth was manned in real time with company personnel who were available for live private chat or to answer questions. Electronic business cards could be exchanged at will. Upon exiting one booth an attendee could then scroll the show floor to enter another. Booths were easily indentifiable by company logos and signage. Feet tired from walking were not part of the experience at FORGExpo 2011, but those whose mouse wrists were tired from the exhibit floor could head to the networking lounge, where they could chat privately in real time with other attendees and colleagues.

Conclusion FORGExpo 2011 was a virtual trade show, but the experience of attending it was no less real than being at a brick-and-mortar event – just different. Moreover, the free registration, as well as the convenience and cost saving of not having to travel, makes the event accessible to many who might not otherwise have approval to attend a traditional trade show. A virtual event is not meant to take the place of a live event held in an urban convention center. Nothing can truly simulate or replace a faceto-face meeting or handshake with a colleague, customer or friend. The forging industry holds many live events, such as Forge Fair, in which forgers gather to view the latest and greatest from their suppliers or hear the most recent industry and technical papers. A virtual exposition is not intended to compete with that. Consequently, FORGE magazine plans to host FORGExpo 2012 on Thursday, Nov. 9, but will not hold one in 2013 – a Forge Fair year. Many thanks are extended to all the exhibitors and attendees who helped make possible a little piece of forging industry history last November. 10

February 2012

FORGEXPO 2011 – AT A GLANCE The following statistics were logged on the actual day of FORGExpo 2011. Archival views through Feb. 10, 2012, are not part of these counts. Number of Registrants: 463, with an attendance rate of 64%. Number of Exhibitors: 18 (including the FORGE magazine booth) Documents Viewed: 1,073 Average Time Spent by Each Attendee: 121 minutes Countries Represented in Attendance: 31 Most Highly Represented Countries (in descending order): United States, India, Canada, Mexico, China, Brazil, Turkey, Colombia, United Kingdom, Argentina, Chile, Germany, Israel. LIST OF EXHBITORS • • • • • • • • • • • • • • • • •

Aberfoyle Metal Treaters All Metals & Forge LLC Alpha-1 Behringer Saws Inc. Bloom Engineering FCI- Forged Components Inc. FORGE magazine Fives North America Forging Industry Association (FIA) Inductoheat Lasco Engineering Services Linde National Machinery Inc. Pemco Schuler Group Simufact True Forge

What They Had to Say About FORGExpo 2011 Exhibitors and attendees had the opportunity to fill out an evaluation form concerning their experience at the virtual event. Many comments were left, and none were negative, but here is a sampling of what those who took part in the virtual event had to say of the experience. ATTENDEES “I found new vendors that I didn’t know existed!” “The presentations of the exhibitors were the most useful.” “I could see Aberfoyle Metal Heat Treaters without a trip and see their operation plus I could obtain information sheets on the capacity of their furnaces. This is a great idea for people who cannot leave their facility for shows. Thanks...” “I think this was a great show. I will attend next year’s event based off this year’s show.” “Presentations were interesting. Easy to get to information in the booths and chat.” “The event looks good. It’s neat to be able to see all of this and not leave my office. Welcome to the new day.” “This is a great idea for people who cannot leave their facility for shows.” “This was a great show. It definitely needs to grow, but otherwise, it has some really great features. The layout was nice, interface was nice, everything flowed really well. It just needs to grow to offer more technology and potential solutions to whatever issues are out there. Great job to the programmers, to the event coordinators, and the event manager. Well done!” “The most useful was the ease to talk with individuals in the booths and come and go and not feel obligated to make small talk.” EXHIBITORS “... for a first experience it was a real good one, with interesting concepts and very useful contacts. Also [this is] a good way for us to [be] more visible in the market.” ”I’ve been impressed with the format, the show is very easy to move around plus easy to communicate.”

TRUST IN RESEARCH www.clearseasresearch.com

“I was really impressed with the format and support by yourself and your colleagues. Very impressive! Let’s do it again.” February 2012

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Distortion in Rolled and Heat-Treated Rings

Forged rings with high outer-diameter to wallthickness ratios are most prone to stresses from manufacturing and heattreating processes. Photo courtesy of Scot Forge.

Jose Gonzalez-Mendez, Alison Duarte Da Silva and Xiaohui Jiang, Graduate Research Associates, The Ohio State University; Taylan Altan, Professor, The Ohio State University The rolling and thermal treatment of forged rings sometimes leaves residual stresses that cause dimensional distortion. Corrective measures in industry are often based on trial-and-error techniques. Ongoing research seeks to base corrective actions on the laws of physics.

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f being rolled at forging temperature, most rings fter aare heat treated (i.e. normalized, quenched and ttempered, see Figure 1). Because of this processing, some rings, especially those with a large outer-dis ameter to wall-thickness ratio, distort and become ovular (out of ll tolerance). This distortion is not the only problem resulting from this phenomenon. Even if the finished rings meet dimensional tolerances and are shipped to the customer, residual stresses resulting from heat treatment may become a problem during subsequent machining, causing additional deformation and distortion. A study on control of distortion and residual stresses in rolled and heat-treated rings is being conducted by the Engineering Research Center for Net Shape Manufacturing (ERC/NSM) in partnership with the Forging Industry Association (FIA/FIERF), Education and Consulting LCC and four forging companies supplying the energy and aerospace industries. Understanding and ultimately solving this problem is a challenging task considering the three triggering mechanisms (thermal, metallurgical and mechanical) that affect the ring during heat treatment and cause the undesired results. In light of the complexity of the problem, most ring-rolling companies approach it with corrective rather than preventive measures. Some manufacture the ring with large tolerances so it can be machined to final dimensions. Others correct the ring distortion by a mechanical method (compression or expansion), which

Normalizing heating (~925˚C, ~2 hours)

Air cooling

also partially relieves the residual stresses. However, mechanical methods are fairly empirical, and there is a need for a physics-based understanding and methodology to produce rings with minimal distortion at an acceptable cost and lead time.

The Process Ring rolling is conducted at a temperature around 2200°F (1204°C). This leads us to an important assumption: the high temperatures at which the ring is being formed will not create any major residual stresses unless the rolling process itself is not well controlled and leads to nonconcentric rings. Consequently, the scope for this project does not include the Finite Element Analysis (FEA) of the ring-rolling process and focuses only on the heat-treatment steps. Before heat treatment, the rings are either arranged individually or stacked in groups of four to six units. Then they are normalized at approximately 1700°F (925°C) for two hours, then air cooled. Industry experience indicates that, although ring stacking will cause nonuniform cooling, the observed distortion is not significant due to the slow cooling rate. Furthermore, the residual stresses developed will vanish in the next heating stage. Prior to quenching, austenitizing is typically carried out at 1515°F (850°C) with the same stack used during normalizing. After exiting the furnace, the rings are submerged into a quench tank. The cooling rate at which the rings reach the bath temperature

Austenitizing heating (~850˚C, ~2 hours)

Figure 1. Commonly used procedures in heat treatment of hot-rolled rings.

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February 2012

Quenching tank (54˚C)

Temperature heating (~590˚C, ~2 hours)

Air cooling

An operator in a control room oversees the ring-rolling line. Photo courtesy FRISA Industries.

should be fast enough to generate martensitic microstructure that will harden the ring material.

Microstructural Issue A microstructural change takes place during quenching. Ideally, the ring has a homogeneous austenitic microstructure at the beginning of this step. Depending on the cooling rate, the microstructure will change to pearlite, bainite or martensite (Figure 2). The amount of transformation will not be the same along the cross section of a ring. How will this affect the distortion and residual stresses development? The strain and stress fields vary with time depending on the thermal and mechanical properties of each phase, which are, in turn, functions of temperature and cooling rate. Also, the volume change at each phase and transformation plasticity during phase transformation should be taken into account. All these factors act together and cause the undesired phenomena, namely that the stresses may exceed the yield point at various locations in the ring. Thus, non-homogeneous plastic flow occurs, causing distortion.

Heat Treatment Finite Element Analysis

culation of stresses and strains through each phase constitutes the mechanical model. For this project we selected an AISI 4140 ring that is geometrically similar to rings produced and heat treated by the sponsoring companies. The dimensions are given in Table 1. To simplify our calculations, we assumed that a single ring is heat treated. In actual industrial settings, only large rings are thermally treated individually, while smaller rings are heat treated in stacks. Table 1. Ring Dimensions Dimensions in mm Outer Diameter (OD)

1,296

Inner Diameter (ID)

1,164

Height (H)

163

Heating Stages for Normalizing and Austenitizing The heating operations for normalizing and austenitizing were simulated for two reasons. First, volumetric expansion of the ring prior to cooling was captured. Second, to corroborate that the heating time is sufficient to achieve homogeneity at the desired temperature. We assumed that at the end of every heating stage and before quenching austenite was formed with volume fraction 1.0 in the ring.

Phase volume, %

Phase volume, %

The commercial modeling program used for this project is DEFORM from Scientific Forming Technologies of Columbus, Ohio. This software allows us to conduct a thermomechanical Air Cooling and metallurgical analysis to predict microstructural changes and Convection, conduction and radiation are the heat-transfer geometrical variations. The phasetransformation model of the mate100 100 rial is determined by the cooling rate Austenite and phase-transformation kinetics. 80 80 Austenite Martensite Since each phase carries particular 60 60 Martensite Bainite thermal and mechanical properties, Bainite 40 40 these factors are integrated into the Pearlite Ferrite model and calculated accordingly. Ferrite 20 20 The thermal component considers 0 0 the heat transfer between the ring 0 200 400 600 800 1000 0 200 400 600 800 1000 Temperature, ˚C Temperature, ˚C and the environment, whether it is air or a quenchant. Finally, the cal- Figure 2. Microstructure evolution in 4140 steel during cooling at: a) 20°C/s and b) 5°C/s. February 2012

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Initial volumetric expansion due to heating prior to quenching

Location of propellers (agitation) varies according to tank design.

X-dimension

1.6 X dimension Y dimension

1.4 1.2

Y-dimension

Quenching tank with agitated solution

Difference between X and Y dimension

1 0.8 0.6 0.4

Z Y

6.15mm

0.2

Y

0

X X

0

5 10 15 Quenching time, min.

20

A zero value would mean that the ring has returned to nominal diameter

Figure 3. Typical arrangement of ring stacks in the quenching tank.

Figure 4. Example of distortion evolution during quenching (diameter comparison between X and Y direction).

mechanisms that act during air cooling. The finite element (FE) simulation conducted considers that after heating for normalizing, two rings are individually placed one next to another on a resting surface. The heat-transfer coefficient with the environment was selected assuming still air, while the conduction coefficient was chosen upon free resting conditions on the surface. The radiation phenomenon was modeled by the Boltzman equation, considering also the proximity effect of an adjacent cooling ring that emits heat.

Quenching The heated rings are submerged in a quenching tank with agitated solution (Figure 3). In order to simulate the quenching, heat conduction of the ring with the quenchant should be carefully modeled. A computational fluid dynamics (CFD) tool depicts the heat-transfer conditions for a particular quenching system. This approach, developed for academic purposes, has some limited commercial application. On the other hand, from an industrial point of view, the number of possible quenching settings and ring geometries make the CFD analysis impractical and expensive. Therefore, we adapted a finite element tool to achieve a close-toreality and practical quenching simulation. The most critical parameter during quenching is the heattransfer coefficient, which depends on temperature, agitation and stacking conditions. Some companies participating in this project conducted temperature measurements on the ring during quenching. This data was later analyzed to calculate the heattransfer coefficient. It is noteworthy that this calculation depicts the specific quenching conditions (location in the tank and in the stack, propeller proximity and orientation) for this ring and

cannot be standardized for any given ring that is quenched in this tank. Figures 4 and 5 show examples of the distortion evolution through time during quenching and the final estimated distortion after heat-treatment simulation, respectively. Here, different values of the heat-transfer coefficient were assumed at various locations in the quenched rings. The reliability of a quenching simulation is conditioned to mostly two things. The first is the precision with which the quenching tank conditions are emulated (in other words, how reliable the heat-transfer calculations are). The second is the accuracy of the mechanical (elastic and plastic), thermal and metallurgical properties of the material to be simulated.

Summary As progress is made, the ERC/NSM is building its knowledge in heat-treatment simulations and recognizing the importance and intricacies of an integrated metallurgical, mechanical and thermal analysis. We can summarize our progress as follows: • Different steps of heat treatment (up to quenching) have been simulated in a commercial FE code in order to predict ring distortion and distribution of residual stresses. • According to FEA results, air cooling will not create any significant distortion (ovality). • Heat-transfer variation during quenching as a function of temperature, tank and stack location, and quenchant agitation is the key factor in calculating distortion, hence the importance of correctly modeling the heat-transfer coefficient. • Through FEA, distortion and residual-stress distribution have been predicted assuming certain quenching conditions.

570

570

499 356

Y O

X

285 214 143

• Maximum deviation from circumference: 6.15 mm • Nominal outer diameter 1296 mm • Geometry with magnified displacement X10

71.3 0.000

Figure 5. Resulting geometrical distortion and residual stresses after FE simulation of heat treatment (original ring dimensions are given in Table 1).

14

428 Y

Y O

X

O

a)

b)

356 X

285 214 143 71.3

Compression stroke

Flat tools Distorted geometry

0.000

Target geometry

Figure 6. Preliminary results for FEA of mechanical correction method (compression): a.) FE setup; and b.) residual stress distribution after corrective method.

February 2012

Effective stress, MPa

Reference geometry

499 Effective stress, MPa

428

Distortion in Rolled and Heat-Treated Rings Our ongoing work focuses on the mechanical methods (e.g., compression or expansion) used by ring-rolling companies to correct geometrical distortion and relieve residual stresses. Our goal is to establish a physics-based methodology that will optimize the procedure used for mechanical correction, i.e. minimum time and best achievable tolerances in concentricity. To this end, we considered the distorted ring geometries obtained from quenching simulations to investigate the compression method by corrective tools already in use. These, in our opinion, are not well understood, since most of this experience is built on trial and error. Our intent is to find a relationship between the distortion-to-diameter ratio and the compression stroke needed to achieve the geometrical tolerances for the ring. Preliminary results (Figure 6) show that a number of compression steps at different locations of the ring will correct ovality and residual stresses are relieved through this plastic strain. Further work needs to be conducted to optimize the process. Co-author Taylan Altan is professor and director of ERC/NSM, The Ohio State University, 339 Baker Systems, 1971 Neil Ave., Columbus, Ohio; 614-292-9267; www.ercnsm.org. Co-authors Jose Gonzalez-Mendez, Alisson Duarte da Silva and Xiaohui Jiang are graduate research associates.

FIERF Industry Collaborative Workgroups Program In the forging industry, problem-resolution projects often occur in isolation at each forger’s site, even though there typically exists a commonality of issues. Small, collaborative work groups across the industry serve to integrate the strengths of participants. Furthermore, forgers often don’t have all the expertise or means available to analyze all aspects of any given problem. This is where FIERF provides the benefit of identifying, selecting and sponsoring specific research programs toward the industry’s collective benefit. Research and development projects can be costly and may not produce immediate commercial benefits, yet they are essential to the long-term financial health of this industry. Joint ventures minimize cost and maximize results. For more information in how to participate, please contact Carola Sekreter at [email protected].

The International Journal of Forging Business & Technology – All You Need to Know About the Forging Industry

www FORGEMAG com www.FORGEMAG.com Kathy Pisano Advertising Director (412) 306-4357; Fax (412) 531-3375; [email protected] Larry Pullman Eastern & West Coast Sales Mgr. (888) 494-8480; Fax (888) 494-8481; [email protected] Steve Roth Midwest Sales Mgr. (520) 742-0175; Fax: 847-620-2525; [email protected] Patrick Connolly European Sales Representative (44) 1-702-477341; Fax (44) 1-702-477559; [email protected] Reed Miller Editor-in-Chief (412) 531-3370; Fax (248) 502-2099; [email protected] Dean Peters Editor (330) 562-0709; [email protected] Doug Glenn Publisher (412) 306-4351; Fax (248) 502-1044; [email protected]

February 2012

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Forgenet International has members on most major continents.

Ten Years of the “New” Euroforge Dr. Theodor L. Tutmann, Secretary General, Euroforge Euroforge, the umbrella organization of the European national associations for the forging industry, has had a checkered history. Among European forgers, the initial contacts and cooperation that began in 1953 continued for several decades. Given changing market conditions, negotiations between the various national forging associations eventually led to the founding of the “New” Euroforge in Paris on Nov. 10, 2000.

I

n the 1990s, the automotive industry and its suppliers changed. What had been national markets served by national industries W became European and global markets. This especially affected b tthe manufacturing sites as well as the purchasing markets of the h automotive industry, which accounted for 60% of demand for European-made forgings – by far the most important customer of Europe’s forges. Thus, the national forging trade associations were increasingly confronted with the cross-border problems of their member companies. As a result, important member companies belonging to their national forging associations (in particular those of Great Britain, France, Germany, Italy, Spain and Sweden) pushed for the establishment of an influential and efficient pan-European platform. Starting in late 1998, the cornerstones of a contract began to be developed. These were to become the basis for Euroforge’s founding meeting in Paris in November 2000. The group’s main objectives were not only to retain members in the Euroforge member associations, but also to gain new members by providing an attractive organizational service platform. In close cooperation with each other, each Euroforge member association has taken responsibility for a particular Euroforge service. The central Euroforge organization has a president, two vice presidents and a general secretary as chairman of the board and is characterized by having a decentralized organizational structure. Euroforge’s General Assembly meets once a year, while the working body of the CEOs of the national member associations, the Board Committee and important working groups all meet regularly twice a year. Only national trade associations can be members, but exceptions can be made where countries have no such association. The tasks of Euroforge are carried out by staff or members of the member associations on an honorary basis.

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February 2012

The Start of the “New” Euroforge On Nov. 10, 2000, the first General Assembly of the “New” Euroforge was held in Paris. The statutes with the decentralized organizational structure were passed and the first budget was Dr. Theodor L. Tutmann is presented. The first president Euroforge’s Secretary General. was Peter Sundström (Sweden). Erwin Peddinghaus (Germany) and Dino Ruffato (Italy) were elected as the first vice presidents, and Dr. Theodor L. Tutmann (Germany) was elected as general secretary. The first official meeting of the Executive Board took place the following day, when the working groups and their assignments were defined and their members appointed. These groups were the Automotive Group, the Open-Die Working Group, the Technical Committee, Statistics and Communication. Additional important activities in 2000 and 2001 were the specific goals for the association’s work, the organization of an Open-Die Working Group and especially the organization of the 17th International Forging Congress (IFC). This global congress, which takes place every three years, was held in Cologne in June 2002 and was a great success. The strategy and working methods of Euroforge found great acclamation. Since that time, Euroforge has profiled itself to become the representative of the European forging industry. On the occasion of the Cologne congress, Euroforge invited for the first time the presidents and CEOs of national forging associations worldwide. Closer cooperation was agreed upon. ForgeNet International,

Ten Years of the “New” Euroforge

Euroforge’s current officers: (left to right) Vice President Alper Kanca (Turkey), President Jose Yudego (Spain) and Vice President Dr. Stefan Witt (Germany)

a global coalition of forging associations from most major continents, was founded. Also, the membership of Euroforge in Clepa (the European Association of Automotive Suppliers) was discussed, and it was passed in 2002. Euroforge is registered in Brussels as an international organization. This enables it, through its national member associations and their member companies, to take part in EU-sponsored projects. In 2003, Finland became the 10th member of Euroforge, and the Turkish association Dövsader was founded with considerable assistance from Euroforge in 2005. In June 2005, the Euroforge Forum Central and Eastern Europe took place in Brno (Czech Republic) with participants from 16 European countries.

Course Adjustments and New Orientation In March 2003, the first signs of a global shortage of steel scrap, resulting from the boom in the Asian steel industry and its consequences, were seen. This problem subsequently was acutely manifest in the form of the termination of all delivery contracts by steel suppliers. As a result of intensive talks with the EU Commission, including suppliers and customers alike, the position of Euroforge and its member companies with steelworks and customers in Europe was considerably strengthened. As a result of all this, Euroforge began a radical course adjustment in 2006, and a new orientation of its work by which the member associations and companies were increasingly integrated into its activities started. Examples of these changes are the alterations agreed upon in the Automotive Group and detailed in a catalog of actions. During the General Assembly in Birmingham (U.K.) in 2006, numerous changes and adjustments to Euroforge’s statutes were passed. An associated membership for members of the OpenDie Forging Group was established by inserting an extra article into the statutes. The Turkish Forging Association was admitted as the 11th member of Euroforge. Jean Louis Deguy (France) was elected as president and José Yudego (Spain) and Erwin Peddinghaus (Germany) as vice presidents. At the General Assembly in Chicago in 2008, the presidency was re-elected until 2010. The delegates of Forge-Net International met on the occasion of this Congress and agreed on Hyderabad (India) as the venue for the 20th IFC, which was held Nov. 13-17, 2011. The General Assemblies and the activities of Euroforge in 2009 were dominated by the economic crisis. Thus, in the technical discussions at the General Assembly in Çesme (Turkey) in

September 2009, along with routine topics, the effects of the recession on Euroforge members was the main point of interest. Staff reductions of up to 50% and loss of turnover of 30% for the passenger car sector and 60-70% for the commercial vehicle sector had occurred along with great financial risks for the companies involved. Strategies for surviving the crisis were considered in the proceedings of the various working groups and were received with great interest. The steel industry was also experiencing collapses in turnover of up to 50%. Position papers on the subjects of retention of title to deliveries to different countries, OEM delivery schedules, a Clepa initiative for the support of automotive suppliers and the planned EU emissions trading law were all presented. In this crisis year, the advantages of having a strong organization and the close cooperation between member associations and companies became very clear. The 2010 spring meeting in Stockholm began with a meeting of the Executive Board. The position paper on delivery schedules was discussed with important OEMs, and a general agreement was reached. Euroforge represents about 70% of European dropforging production. In September 2010, the 10th Annual Meeting of Euroforge took place in Brussels. The main points of interest were market trends in Asia, North America and Europe, which were dealt with in three working groups within the meeting of the European Automotive Group, and the election of the new Euroforge presidency with José Yudego (Spain) as president and Dr. Stefan Witt (Germany) and Alper Kanca (Turkey) as vice presidents. On the occasion of the 10th anniversary of the founding of the “New” Euroforge, the president of Businesseurope, Jürgen R. Thumann, the president of the North American Forging Association, Kevin Crowley, and the General Director of Clepa, Lars Holmqvist, were invited as guest speakers. After a decade in a leading role in Euroforge, retiring Vice President Peddinghaus gave a review of these 10 years of successful work for the European forging industry. Dr. Theodor L. Tutmann is the current Secretary General of Euroforge, whose offices are in Hagen, Germany. He may be reached at [email protected]. A brochure issued on the occasion of the 10th anniversary of the “New” Euroforge can be ordered free of charge from Ingrid Schallnus, [email protected]. For more information, visit www.euroforge.org February 2012

17

COMPANY C OMPANY PROFILE

Lehigh Heavy Forge: Long History, Large Parts Lehigh Heavy Forge Corporation (LHF) of Bethlehem, Pa., is the sole remaining super-heavy open-die forging company in the Western Hemisphere. More than a century old, the company’s historic facilities were the birthplace of the modern U.S. defense industry.

I

A large shell is removed from heattreating furnace for quenching.

n the 1880s, the U.S. Navy wanted to convert its fleet from Today, LHF is a leader in the production of components for the w wooden ships to iron-clad vessels. They asked what was Navy, pressure vessels, commercial nuclear forgings, large-diameter tthen the Bethlehem Iron Works to build a forge shop to backup rolls, work rolls, power-generation equipment, marine ssupply the necessary armor plate and gun tubes, offering a equipment, ship shafting, billet and large industrial components. $9 million il order to facilitate the construction. In 1887, the BethPrecision Forging and Other Capabilities lehem Iron Company installed two hydraulic forging presses – For more than 120 years, LHF has been producing large open-die one 2,000 ton and one 5,000 ton – along with the appropriate heatforgings for critical applications. All of the manufacturing steps treatment and machining facilities to satisfy the Navy’s orders. Ever are controlled by strict manufacturing plans. The large forgings since, the plant has been a vital supplier of critical components to produced at LHF require highly refined steel made from ingots the Navy. weighing up to 300 tons teemed at ArcelorMittal’s Steelton Plant. The Bethlehem forging plant went on to solidify its role as an Steel for LHF’s heavy forgings is melted in an electric arc furnace internationally renowned leader in the production of quality forgand ladle refined to consistently meet restrictive chemical and ings. The company dominated the market for large forgings for the cleanliness requirements. From there, the steel is double degassed – electric power-generation industry, producing the forgings for the ladle degassed while being argon stirred followed by Vacuum large hydroelectric plants built near Niagara Falls. The company Stream Degassing (VSD) – a process pioneered in Bethlehem in also produced the axle for the Ferris Wheel of the 1892 Chicago the 1950s. With both degassing operations occurring at less than World’s Fair. Weighing 56 tons, it was then the largest forging ever 1 torr, the process removes detrimental levels of hydrogen. Once produced. solidified, the ingots are shipped hot to LHF’s Bethlehem facilities. Over the years, several different forging presses were built at the site. The current 10,000-ton computercontrolled oil-hydraulic open-die forging press was erected in 1983. The press continues to be the largest open-die press in the Western Hemisphere. The smaller 3,000-ton press was converted to oil hydraulic in 1998. The name of the facility also evolved with the passage of time in several steps to BethForge, a subsidiary of Bethlehem Steel Corporation. In 1997, Whemco Inc., a Pittsburgh-based supplier of heavy industrial components, preserved the facility by purchasing it from Bethlehem Steel and renaming it Lehigh Heavy Forge. Since the acquisition, significant investments have been and continue to be made in press and manipulator upgrades, forge and heattreatment furnace rebuilds, and the addition An ingot is being prepared to be shipped to LHF’s Ingot being blocked under LHF’s and modernization of machine tools. Bethlehem facilities. 10,000-ton press. 18

February 2012

A workpiece is upset under LHF’s 10,000-ton press.

A ship’s shaft is forged on the 10,000-ton press.

The centerpiece of any forging operation is the forging press. LHF has two open-die forging presses: a 3,000-ton press for billets and work rolls and a 10,000-ton press for making large parts. Both press lines have rail-mounted manipulators and auxiliary water cranes to permit the forming of complex shapes. When ingots arrive, they are heated to forging temperatures in large car-bottom furnaces prior to deformation under the press. Once forging is complete, the newly formed part undergoes a preliminary heat treatment in certified furnaces up to 16 feet in width and 70 feet in length. For the quality final heat treatment, depending on the material and desired properties, the large pieces can be quenched in water, oil or air. The quench tanks include deep horizontal designs 51 feet in length by 11 feet in depth as well as vertical tanks 22 feet in diameter by 15 feet in depth. For certain applications, spray quenching or cryogenic treatment boxes are also used. To verify that the required mechanical properties are met, LHF has an in-house testing laboratory where tensile and Charpy specimens are tested with a temperature range capability of -320°F to 350°F. The lab also performs hardness testing, macro etching and various metallographic inspections. LHF’s machine shop houses large computer-controlled machine tools. There are 11 CNC lathes up to 80 feet in length, with up to a 100-inch swing. The company’s boring capabilities are unique, with two boring lathes capable of trepan boring shafts up to 80 feet long from one end. If required, the bore can be finished on either of their two 80-foot-long honers. Parts with unique geometries are machined on one of nine horizontal boring machines, four of which are CNC-controlled with spindles up to 10 inches in diameter. Pressure-vessel cylinders, discs and domes necessary for the commercial nuclear industry are machined on one of the company’s seven vertical boring mills. With CNC vertical mills up to 25 feet, many shapes and configurations are possible. Additionally, the company has a host of other equipment like planer mills, band saws, and CNC and conventional grinders. Governed by LHF’s quality system, which is ISO 9001-2008 registered, the forgings are checked to ensure a high level of quality before, during and after machining. All quality control testing is conducted by personnel who are qualified to perform ultrasonic, liquid penetrant, magnetic particle and dimensional inspections.

A heavy-wall cylinder is machined on a 25-foot vertical boring mill.

A senior-level nondestructive-testing engineer oversees all inspections. All measuring instruments are certified by the in-house metrology laboratory, and the pyrometry lab certifies the temperature-measuring devices.

Large Forgings for Large Operations The components that LHF produces are critical to many industries, including defense, steel production, fossil-fuel power generation, hydropower generation, commercial nuclear-power generation, mineral processing and mining, marine equipment, and other general industries. For the steel industry, the company produces backup rolls, including plate-mill backup rolls weighing in excess of 150 tons. LHF is also a global supplier of work rolls to the world’s rolling mills. Fossil power-generation components produced include generators, turbine rotors, discs, couplings and jackshafts. Heavywalled cylinders and shafts for generators are made for the hydropower industry. Pressure-vessel components such as domes, heads, discs and heavy-walled cylinders are produced for the commercial nuclear power and other industries. Many different types of shafts are produced for various uses in the mining industry – rock crushers, drum shafts, draglines, etc. LHF forges propulsion shafts and rudder stocks for the shipbuilding industry. Forgings for nuclearpowered Navy ships are also produced. Custom components for press building include platens and tie rods to die blocks.

Expansion Ahead LHF is currently planning a multimillion dollar expansion that will eventually increase its capacity to process large forging ingots by 100%. All of the design and engineering for the expansion, which will be done in phases, has been completed. The expansion’s initial phase will increase ingot processing capacity by 40%. Subsequent phases will increase the ingot quantity by 100%. This move in the face of economic uncertainties is evidence that LHF plans to strengthen its position in the large open-die forging market. With the expansion, Lehigh Heavy Forge will be able to provide reduced lead times on large forgings. For further information on Lehigh Heavy Forge, readers may call 610-332-8100; fax 610-332-8101; e-mail [email protected]; or visit www.lhforge.com. All photos courtesy of Lehigh Heavy Forge. February 2012

19

Feature Article Index (2006-2011)

T

his issue of FORGE marks the beginning of its sixth year of publication, an event of which we are very proud. A great deal of information has passed through our hands and eventually onto our pages and website over that period of time. Some information, such as that contained in our news pages, is time-sensitive and diminishes in value. Fortunately, most of what we publish, such as our feature articles, is more enduring. Readers who have archived our issues are in possession of a resource. To help readers better utilize this resource and more easily find the information they seek, we offer this index – by major category – of all our feature articles to date. – Dean M. Peters, editor

AUTOMATION “Forge Shop Automation – Part II” – Jan Hutson, Rimrock Corp.; July 2009, p. 23 “Forge Shop Automation – Part I” – Jan Hutson, Rimrock Corp.; April 2009, p. 20

“Specialty Ring Products – Lords of the Ring” – October 2008, p. 20 “Trinity Forge: Growth Through Full Service” – July 2008, p. 19 “Bula Forge Provides Creative Solutions” – April 2008, p. 17 “Keystone Forging Find its Niche in a Competitive Industry” – January 2008, p. 21 “ZKM Forging (Poland) – Evolving into an Aerospace Forge Shop” – January 2008, p. 17 “Consolidated Industries – Flying High in Aerospace” – October 2007, p. 18 “Alcoa Wheel Products Division Shines Brightly” – July 2007, p. 14 “Ladish Plots its Path to Growth” – April 2007, p. 13 “Firth Rixson, Ring Leader” – November 2006, p. 15

COMPANY PROFILES “Precision Metal Products Strong on Aerospace and Defense” – November 2011, p. 21 “California Drop Forge Serves the Aerospace Industry” – July 2011, p. 24 “Midwest Tool and Cutlery Expands its Commercial Business” – January 2011, p. 19 “Demshe Forge – Two Forges on One Site” – July 2010, p. 25 “Green Bay Drop Forge Hammers Out its Future” – April 2010, p. 31 “Fox Valley Forge Seeks Growth in New Markets” – January 2010, p. 7 “Ohio Star Forge Grows Through Diversification” – October 2009, p. 20 “Wodin Promises Service, Commits to Quality” – July 2009, p. 11 20

“Rotek Helps Industry Get Its Bearings” – April 2009, p. 13

February 2012

COMPUTER MODELING & SIMULATIONS “Computer Modeling of Induction Heating Processes – Part 2” – Dr. Valery Rudnev, Inductoheat Inc.; October 2011, p. 25 “Tips for Computer Modeling Induction Heating Processes – Part 1” – Dr. Valery Rudnev, Inductoheat Inc.; July 2011, p. 21 “Induction Heating Process Simulation for Forging” – Donald A. Gibeaut and Stephen H. Klostermeyer (ABP Induction) and Arjaan Buijk (Simufact Americas); July 2010, p. 13 “Understanding Geometrical Forging Defects” – John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); April 2007. p. 8 “Using Process Simulation to Optimize Forging Processes” – Michael A. Foster and Christian E. Fischer, Scientific Forming Technologies Corporation; January 2007, p. 10

FORGE Feature Article Index CONFERENCES & MEETINGS “IFM 2011 a Hit in Pittsburgh” – Dean M. Peters, FORGE editor; November 2011, p. 13 “FIERF Holds 28th Forging Industry Technical Conference” – Dean M. Peters, FORGE editor; July 2011, p. 17 “19th International Forging Congress Held in Chicago” – Dean M. Peters, FORGE editor; October 2008, p. 24

CUTTING EQUIPMENT “Saw Manufacturer Keeps Edge in Dull Economy” – July 2011, p. 19

DIES & DIE MAINTENANCE “Predicting Individual Die Loads in Multi-Stage Forging” – Dr. Judy Jin, University of Michigan; April 2011, p. 27 “Novel Forging Tool Design Improves Efficiency” – Judith Kerkeling, Karsten Müller, Dr. Rouven Nickel and Prof. Dr.Ing. B.-A. Behrens (Institut für Integrierte Produktion Hannover gemeinnützige GmbH); January 2011, p. 15 “Die and Equipment Welding in the Forge” – Darryl S. Hammock, Weld Mold Company; April 2010, p. 25 “Die Spray Techniques for Forgers – Part II” – Michael D. Forster, Girard Engineering Company; July 2010, p. 21 “Die Spray Techniques for Forgers – Part I” – Michael D. Forster, Girard Engineering Company; April 2010, p. 15 “Optimizing H-13 for Forge Tooling” – Steve Englet, Ashland Precision Tooling; January 2010, p. 14 “Forging-Die Material Development: From Research to Implementation” – Patricia Miller, Bohler-Uddeholm Corp.; April 2009, p. 24 “Surface Modification Techniques for Forging Dies” – David Pye, Pye Metallurgical Consulting; January 2009, p. 17 “Die Maintenance in the Forge Shop” – David Fox, Weld Mold Company; July 2008, p. 11 “The Basis of Forging-Die Failures – Part 2: Case Studies” – John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); April 2008, p. 25 “The Fundamental Basis of ForgingDie Failures – Part 1” – John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School

of Mines); January 2008, p. 9 “Reducing Forging-Die Costs and Lead Times” – James R. Knirsch, RSP Tooling; October 2007, p. 15 “Welded Repairs Extend Forging Die Life” – Darryl Hammock, Weld Mold Company; April 2007, p. 17

FORGING EQUIPMENT “Isolating the Vibrations of Forging Hammers” – Steve Veroeven, PE, Vibro/ Dynamics Corporation; October 2010, p. 19 “Tonnage Monitoring for Mechanical Forging Presses” – Steven F. Rasmussen, Angstrom Corporation; October 2010, p. 15 “Tonnage Monitoring for Hydraulic Forging Presses,” – Steven F. Rasmussen, Angstrom Corporation; July 2010, p. 17 “Comparative Analysis of Forging Presses” – John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); January 2010, p. 11 “Hydraulic Presses Offer Production Flexibility, Accurate Control” – John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); July 2009, p. 19 “Pressing Matters: A Primer” – C.J. Crout (Ajax-CECO), John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); April 2009, p. 17 “Forging Equipment – Hammers” – C.J. Crout (Ajax-CECO), John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); January 2009, p. 10 “Screw Presses Offer Versatility and Precision” – Roger Rees (SMS Meer), John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); October 2009, p. 16 “Advanced Hydraulics Helps You Save on Forge Press Operations” – G. Ian Fielding, Kadant AES; April 2007, p. 20

LUBRICANTS & LUBRICATION “Lubricants for the Nonferrous Forging Industry” – John Kondilas, Dylon Industries; October 2009, p. 12 “A Closer Look at Forging Lubricants” – Jeff Zdilla and David Poole, Dylon Industries; January 2009, p. 13

February 2012

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FORGE Feature Article Index MANAGEMENT

SUPPLY-CHAIN MANAGEMENT

“FIERF Celebrates Golden Anniversary” – Dean M. Peters, FORGE editor; November 2011, p. 19

“Steel Distributors Help Control Risk” – Wendell MacDonald, Turret Steel Industries and Sunbelt-Turret Steel; October 2010, p. 23

“Starting Your Job Shop on its Lean Journey” – Dr. Shahrukh A. Irani, The Ohio State University; April 2008, p. 13

“Forging Procurement, Military Style” – July 2008, p. 23

MARKETS & APPLICATIONS “Forged Crankshafts Outperform Castings, Offer Benefits” – Richard F. Grimes (Gerdau Special Steel) and David Anderson (Steel Market Development Institute); October 2011, p. 17 “Forged Titanium Domes Will Help Explore the Deep” – July 2009, p. 15 “Forging an Opportunity: Wind Turbines” – Dean Peters, FORGE editor; October 2008, p. 13 “Outlook 2008: Another Good Year Ahead” – Dean Peters, FORGE editor; October 2007, p. 12 “The Changing World of Automotive Forgings,” – Dean Peters, FORGE editor; November 2006, p. 18

MATERIALS “Forging Materials: Microalloyed Forging Steels” – John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); November 2011, p. 15 “Forging Materials: Stainless Steels” – John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); October 2011, p. 21 “Forging Materials: Plain-Carbon and Low-Alloy Steels (Part II)” – John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); April 2011, p. 23 “Forging Materials: Plain-Carbon and Low-Alloy Steels (Part I)” – John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); January 2011, p. 12 “Understanding Material Forging Defects” – John Walters (Scientific Forming Technologies Corp.) and Dr. Chet Van Tyne (Colorado School of Mines); July 2007, p. 17

THERMAL EQUIPMENT AND PROCESSING “Computer Modeling of Induction Heating Processes – Part 2” – Dr. Valery Rudnev, Inductoheat Inc.; October 2011, p. 25 “Tips for Computer Modeling Induction Heating Processes – Part 1” – Dr. Valery Rudnev, Inductoheat Inc.; July 2011, p. 21 “Advanced Oxy-Fuel Burners and Controls Improve Fuel Savings and Uniform Heating” – Larry Cates and Rick Browning, Praxair Inc.; January 2011, p. 9 “Ensuring the Quality of Inductively Heated Billets” – Gary Doyon, Doug Brown and Dr. Valery Rudnev (Inductoheat Inc.) and Dr. Chet J. Van Tyne (Colorado School of Mines); April 2010, p. 19 “The Importance of Normalizing” – Daniel H. Herring, The Herring Group; April 2011, p. 15 “Induction Heating Process Simulation for Forging” – Donald A. Gibeaut and Stephen H. Klostermeyer (ABP Induction) and Arjaan Buijk (Simufact Americas); July 2010, p. 13 “Successful Induction Heating of RCS Billets” – Dr. Valery Rudnev, Inductoheat Inc.; July 2008, p. 15 “Normalizing Forged Aerospace Components” – David Pye, Pye Metallurgical Consulting; April 2008, p. 21 “Modular Induction System Offers Billet-Heating Advantages” – Douglas R. Brown, P.E., Inductoheat, Inc.; January 2008, p. 13 “Controlled Cooling Improves Forging Quality, Throughput and Cost” – Andrew L. Banka and Jeffrey D. Franklin (Airflow Sciences Corporation) and B. Lynn Ferguson (Deformation Control Technology Inc.); October 2007, p. 21 “Thermal Treatment Extends Forging-Die Longevity” – Michael Moyer and Robert Lacock, Solar Atmospheres Inc.; July 2007, p. 11 “The Use of Conventional Furnaces in the Forging Industry” – Paul Huber, SECO/WARWICK; January 2007, p. 13

QUALITY & TESTING “NDT Lab Strengthens its Aerospace Supply-Chain Link” – April 2011, p. 19 22

“Securing the Supply of Forgings for the Military” – Jon Tirpak, ATI; November 2006, p. 7

February 2012

“Induction Heating Serves Today’s Forging Industry” – Dr. Valery Rudnev, Inductoheat Inc.; November 2006, p. 11

advertorial

A. Finkl & Sons, Co.

A.

A. Finkl & Sons, Co. ................................ 23 www.finkl.com Ajax-CECO ............................................. 24 www.ajax-ceco.com Alfe Heat Treating................................. 25 www.al-fe.com

Finkl & Sons, Co. is a fully integrated steel mill committed to producF ing in high-quality specialty steel. Since 1879, A. Finkl & Sons, Co. has emerged to become the dominant producer of forging die materials. It em iis through th h the th use of modern manufacturing technology, thorough quality assurance procedures (ISO 9001 certified) and robust inspection methods that ensures consistent die-steel quality in every heat of steel produced. Finkl products include a family of die steel that will meet the needs of today's most challenging forging applications. Forging applications in both hammer and press operations that require a die steel to have the perfect balance between fracture toughness and wear-resistant properties. Finkl is truly THE NAME in Die Steel! For more information, please visit our website at www.finkl.com.

All Metals & Forge Group, LLC ................. 26 www.steelforge.com Alpha 1 Induction Service Center ........... 27 www.alpha1induction.com COR-MET Inc.......................................... 28 www.cor-met.com Ellwood Specialty Steel ......................... 29 www.elwd.com LASCO Engineering Services ................... 30 www.lascousa.com Shandong Iraeta Heavy Industry Co. Ltd. 32 www.shandongiraeta.cn

The Diamond

is Getting Bigger

Siempelkamp ....................................... 34 www.siempelkamp-usa.com Superbolt ............................................. 36 www.superbolt.com Weld Mold Company ............................. 33 www.weldmold.com

BIGGER • 45 acre site • 12 acres under roof • 500 ton crane capacity • Over double the forging capacity

FASTER • 90 ton EAF powered by 75 MVA transformer • SMS Ladle Metallurgy Furnace • Automated Alloy Addition System • 400,000 Ingot Tons

STRONGER • 8000 ton press • Designed by Finkl engineers • Assisted by 60 and 100 ton manipulators • Press/Manipulator Integration

A. Finkl & Sons 2011 N. Southport Ave., Chicago IL 60614 U.S.A. (773) 975-2510 Employment Opportunities at www.finkl.com

February 2012

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advertorial

Ajax-CECO

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h New #38 Die Forger is the latest update to the popular Die he Forger line. It features patented dual inlet and exhaust valves F tthat extend the useful energy range to 10% of rated power while rretaining the capacity for the full power potential of this large ((8,000-pound falling weight), modern hammer. The added versatility remarkable when compared to older models. tilit is i truly t The Die Forger is PLC controlled and programmed with a color HMI for simplicity of operation and enhanced troubleshooting. The Die Forger’s productivity is unmatched due to its high blow rate. Its ease of programming makes the operator more efficient because hammer control is under the direction of the PLC. Our users report that you can expect higher quality forgings from this latest Die Forger – a big plus in today’s demanding world where quality, price and delivery are critical.

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Februar y 2012

advertorial

Alfe Heat Treating Dependability. Quality. Results.

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h hose three words are often lost in the rush to get to the top, but at Alfe Heat Treating, the largest commercial to aluminum heat treater in the U.S., those words are al the foundation of everything that we do. We built th our business from the ground up, one job at a time, o by consistently providing excellent results. From prototypes to b i large-volume jobs, from castings to forgings, Alfe can handle the work, meeting whatever challenge you bring our way. We work in all industries – aerospace, military, automotive and commercial products – handling both ferrous and nonferrous materials. Quick turnaround times mean most jobs are processed within 48 hours, keeping your production schedule on track. We’ve provided parts for projects as big as the space station and as small as replacements for a single airplane. We’ve worked with the best and brightest in the industry, from Eaton to Boeing, and everything in between. Our long list of approvals and certifications, including Nadcap accreditation and registration to ISO, gives our customers reassurance that every part meets

industry specifications and attains world-class quality standards. When you work with Alfe, you work with the best … and you get the best results.



February 2012

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advertorial

All Metals & Forge Group

A

316”MAXIMUM O.D. 6” MINIMUM O.D. UP TO 40,000LBS ALLOY ‹ CARBON ‹ TOOL STEEL STAINLESS ‹ NICKEL ALUMINUM ‹ TITANIUM

ISO9001:2008/AS9100B/EN9100 Cert. No. 2009-01874-R2

75 LANE ROAD, FAIRFIELD, NJ

TOLL FREE: 800.600.9290

STEELFORGE.COM

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February 2012

ll Metals & Forge Group (AM&FG) is an ISO 9001:2008/AS9100 REV B/ EN9100-registered forging manufacturer and supplier of seamless rolled E rrings. AM&FG specializes in specialty steels, alloy steels, carbon steels, aluminum alloys, stainless steels (200, 300, 400, 500 series), PH grades, nickel alloys, titanium alloys, tool steels, and superalloys. AM&FG also supplies corrosionand heat-resistant alloys. AM&FG’s Forge Division has the capacity to forge seamless (and contoured) rolled rings up to 316 inches in diameter, blocks, discs, shafts, flanged shafts, long shafts, step shafts, cylinders, blind cylinders and hubs up to approximately 75,000 pounds. AM&FG prides itself on its ability to forge and machine complex, heavy parts. Our corporate goal is to have competitive prices, reliable deliveries and, above all, a sales team that is helpful, courteous and professional to meet our clients’ requirements.

The International Journal of Forging Business & Technology – All You Need to Know About the Forging Industry Becky McClelland (412) 306-4355 • [email protected] Kathy Pisano (412) 306-4357 • [email protected] Larry Pullman (888) 494-8480 • [email protected] Steve Roth (520) 742-0175 • [email protected] Patrick Connolly (44) 1-702-477341 • [email protected] Reed Miller Editor-in-Chief (412) 531-3370 • [email protected] Dean Peters Editor (330) 562-0709 • [email protected] Doug Glenn Publisher (412) 306-4351 • [email protected]

www.FORGEMAG.com

advertorial

Alpha 1 Induction Service Center

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l lpha 1 Induction Service Center, an Inductotherm Group Company, is a premiere manufacturing and repair facility for induction load coils of aall types. The company can also manufacture and repair some types of and most water-cooled cable assemblies. Alpha 1 Induction Service ttransformers f Center has incorporated years of experience and technology advances to provide its customers with fast, efficient and high-quality repairs, all in an effort to keep its customers up and running and making money for their investors. Because of its depth of experience, Alpha 1 has developed a line of material-handling equipment for the forging industry, including our continuous bar feeding equipment, billet elevator feeders, bin tippers, conveyors and billet extractors, which will be marketed by Alpha 1 and several of the Inductotherm Group companies. Please contact Alpha 1 Induction Service Center at 614-253-8900 with any questions or to request a quotation.

TECH Spotlights Are Also Available as REPRINTS If it’s been printed in FORGE, you can have it reprinted by FORGE. Feature Articles, Technology Spotlights, Company ProÀles, News Releases or Product Information. Customize your reprints with your company’s ad, special message or even the cover of FORGE.

Contact Becky McClelland at 412-306-4355 for details

February 2012

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advertorial

COR-MET Inc. Forge Die Repair – Flood-Welding Procedure

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O OR-MET is a world leader in the manufacture of flux cored welding wire and stick electrodes, o sspecializing in high-deposition alloys for the repair of forging dies and large foundry castings. The floodo welding technique can deposit up to 60 pounds per w hour off weld h ld metal using equipment such as the Wire Welding Stick®, Electrode Welding Stick® and Hand Welding Stick®. The consumables available for flood welding include: low-carbon steel, multiple NiCrMo alloys, chrome hot-work alloys and high-nickelbase alloys. The product forms available for flood welding are flux cored wire (3/32”, 1/8” and 5/32” diameter) and Stick Electrodes (sizes up to 20 mm diameter x 39” in length). TYPICAL FLOOD-WELDING PROCEDURE Preparation: Remove worn or cracked material from the area to be welded. This may be done by air-carbon arc gouging, oxygen acetylene torch or machining. Preheat: Preheat according to base metal and weld metal chemistry. The most common preheat temperature is 800°F, and the interpass temperature range is 600-800°F. Welding: Weld with appropriate COR-MET Stick Electrode or Flux Cored Wire. Contact COR-MET for the proper welding alloy and flood welding equipment selection. Peening: Peen the weld area to reduce shrinkage stresses and crater cracking. Peening will refine the grain structure and is most beneficial while the weld bead is in the red condition. Post-heat and Cooling: After welding, equalize in the interpass temperature range. Cover with insulation or place in a furnace. Slow cool to room temperature. Temper: Stress relieve or temper to desired hardness. *Flood welding is used most effectively for providing labor cost savings.

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The Wire Welding Stick® and The Electrode Welding Stick® are registered trademarks of COR-MET Inc.

advertorial

Ellwood Specialty Steel

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x xELL ForgeDie™ was developed by Ellwood Specialty SSteel (ESS) as a new die steel for hot forging aapplications. Using an economical, low-alloy steel design, ExELL ForgeDie offers cost savings compared d tto conventional, higher-alloyed die steels. The steel composition, micro-cleanliness and heat treatment have been composition optimized to provide: • • • • • • •

Resistance to softening at elevated operating temperatures Resistance to thermal fatigue Good impact toughness Hardenability in large cross sections Machinability Weldability Capability for surface hardening

These properties are attainable while using an alloy chemistry that balances the content of expensive elements such as nickel, molybdenum and chromium to achieve desired performance for the end user at an improved cost. ExELL ForgeDie is processed using clean steel technology, including ladle refining, vacuum degassing and bottom-poured ingot techniques, to produce an alloy with minimum nonmetallic inclusions and internal segregation that dictates a sound, solid as-cast structure. Then, tightly controlled ingot forging practices to die block sizes assure thorough mechanical hot working of the

alloy structure so that physical properties are repeatable. Finally, heat-treating processes have been honed to produce prehardened microstructures that can be relied upon to perform in the tough applications of the forging industry while maintaining the machinability desired by die makers. Through its composition, ExELL ForgeDie also enables weld repair and enhanced surface treatments that can extend the useful life of forge tooling. Since its introduction to the market, more than 15 million pounds of ExELL ForgeDie have been produced and supplied to customers forging a wide variety of products made in impression dies. Hammer shops have reported much improved die wear in their most difficult applications, and press shops have experienced less gross cracking or high-temperature softening when compared to competing steels. In addition, ESS has documented consistent hardenability in large-section blocks and rounds. Surface to center hardness readings of BHN 352-388 (Rockwell C 38-42) assure consistent through-hardening for reliable die sinking and in-press performance. Tools used to produce impression die forgings are high-value, critical components. To maximize the return on investment, early catastrophic die failure must be avoided and “normal” wear and damage must be minimized. The selection of a steel alloy for forge tooling can be a critical factor in avoiding costly replacement or repair of dies as well as lost production, late deliveries and unhappy customers. Consider what ExELL ForgeDie can do for your impression die forge tooling applications.

February 2012

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advertorial

LASCO Engineering Services

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h development of the fully automated forging hammer he was considered a monumental achievement in 2002. w Now the patented technology has been proven with N nearly 30 production lines spread over Europe, Asia and n tthe United States. The forging lines are currently operated d in a wide d variety of settings, from automotive production to job shops. Recently, LASCO successfully automated a die forger at a U.S. forging company. ENGINEERING There are no “cookie cutter” solutions that apply to automation, as every product and company has different demands. LASCO starts the process of automation by listening and observing. Through this process we can understand the tasks that need to be fulfilled. The most important factor for a successful installation of automation is the amount and competency of the engineering. LASCO has a staff of 61 degreed engineers who understand the process of forging and the demands placed on the equipment. The longevity of the equipment is one portion of the process, but making the automation easy to use is equally as important. CONTROLS The key to making the automation easy to use is a straightforward control system for the operators and setup people to interface with. The language of the LASCO controls is customized to use the terms the customer is used to, and programming is easy to learn. The operators of the line don’t need to go to any robotic programming training to use the system because the whole setup can be conducted through

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February 2012

the menu windows of the operator panel. The beginning screen allows the operator to select the number of impressions in the die, what type of impression each one is (flattener, blocker, etc.), the sequence that the impressions are used, etc. As these questions are answered, the program for the robots and the blow sequence and intensity of the hammer is automatically set up for the operator. DIES The dies are able to be modified or can easily be designed for the automation process. LASCO engineers provide sketches and rules that can be followed to provide for the automation, then check and help with the design of the first few dies as needed. One benefit to automated systems is a marked improvement in die life. This is attributed to the consistency of the cycle. CHANGEOVER Everyone is concerned with the amount of labor and downtime associated with changing dies over in the hammer. A patented probe is used to determine the die position in the hammer. Other mechanical adjustments are made easily, and then the program is recalled from the computer’s memory. Complete changeover times can be less than an hour. For more information: LASCO Engineering Services, LLC 1111 Bellevue Ave., Detroit, MI 48207 313-579-7169 [email protected]; www.lascousa.com

advertorial

Shandong Iraeta Heavy Industry Co., Ltd.

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h handong Iraeta Heavy Industry Co., Ltd. recently took on the task of a 5-megawatt (MW) offshore to wind-turbine system tower flange for Sinovel after w successfully developing a 3.6-MW offshore windsu turbine bi system tower flange. The 3.6-MW offshore wind-turbine system tower flange, which works as an important structure in the system, was successful off the assembly line and was the largest in the Chinese wind-turbine manufacturing industry. The 5-MW flange would break this record again. For an order of 5-MW tower flanges, every set includes 12 pieces. The maximum cutting weight for a single piece is more than 17 tons, the maximum outer diameter is 6,320 mm, the wall width is 385 mm and the height is 175 mm. The forging ratio is 16.02, which is difficult for overall forging, and has strict requirements for forging equipment (oil pressing machine, rolling machine), heat-treatment equipment and forging processes. The smallest top flanges have an outer diameter of 5,000 mm, total height of 370 mm and hole depth of 300 mm. The requirements for machining and drilling machine capacity are more strict than for past products. Considering the double load of sea wind and wave, the atrocious climate as well as complex variable elements like salt mist and waves, the requirement for the strength and stability of tower

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February 2012

flanges is much more strict, after test, than the yield strength of basic rings. Basic rings, or bottom flanges, have tensile strength of 530Mpa, elongation rate of 23%, and reduction rate in section of 76%. The impact test in low temperature is 137J (-50°C) and grain size *8 level, which exceeds the product specification requirements. The 5-MW overall forging doorframe flanges, which match the 5-MW wind-turbine system, are also produced by Shandong Iraeta. The thickness (300 mm) of the doorframe flanges has far exceeded the past doorframe thickness of 100-200 mm, which was produced by Shandong Iraeta in the past. In 2010, to adapt the changing market, the company transferred the production from low-power wind-turbine system tower flanges to high-power wind-turbine system tower flanges. Shandong Iraeta also transferred the service from land-based wind power to offshore wind power and processed the tower flanges with non-equidistant, large hole diameter and deep holes. These changes reveal the continually upgraded technology and competitiveness of Shandong Iraeta. At the same time, the company pays attention to improve its worker’s personal quality, continually inputs new technology, improves process and test equipment capacity, and improves production processes and test levels. In 2011, Shandong Iraeta will continually strive to build a world-class wind-power flange.

advertorial

Weld Mold Company The Birth of Floodwelding g

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n the words of Matt Kiilunen (1905-1990), founder of Weld Mold Company, “…one of the outstanding jobs was as the flooding of a completely scarfed out forging-die cavity ty with our weld metal; and the results were satisfactory. I believe it was the first welding of its kind ever attempted, d, and d off course since then we have continuously welded dies for them m and saved them hundreds of thousands of dollars.” This test was as completed in 1952 and comes from Mr. Kiilunen’s autobiography, y, which was written in 1972 and revised in 1978. This was the birth of floodwelding as we know it today. This is test spawned a worldwide industry of independent and captive ve forge-shop welding operations, all using a composite of alloys and d the floodwelding process providing tremendous savings to their ir customers by eliminating or greatly reducing scrap and extending ng die life and making possible the forging of today’s exotic alloys. Floodwelding is a high-deposition welding process using largeediameter welding electrodes (up to 1 inch diameter and 4 feet in n length) or large-diameter (up to 3/16 inch diameter) flux cored wires. Deposition rates can exceed 100 pounds per hour of weld metal, saving tremendous time and ending scrapped die steels, bases, columns, rams and other components. Dies and other weldments can be ready for machining after a thorough stress-relieve and tempering cycle – in days vs. weeks. The progression of Weld Mold Company and the development of floodwelding is fascinating: • As early as the 1930s, small-diameter electrodes were used for forge-shop repairs. The alloys available could not withstand the high heat and impact requirements of forging applications. The deposition rate was a maximum 5 pounds per hour. Weld Mold Manipulator

Weld Mold ARM (inset top: large dipped rod; inset bottom: pack rod)

• Weld Mold Company was founded in 1945 to develop welding materials for the forging industry. • “Pack Rod” was invented by welding a number of small rods together (circa 1947). See photo attached. • Large-diameter hand-dipped rods (vs. extruded) were attempted and successful (circa 1948). This improved the deposition rate to an estimated 15-20 pounds per hour. See photo attached. • The Weld Mold “ARM” was invented in 1950s by Matt Kiilunen. See photo attached. • In 1955, Weld Mold purchased its first extrusion press capable of producing ½-inch-diameter electrodes. • Weld Mold began extruding ¾-inch-diameter welding electrodes around 1965. • In 1972, Matt Kiilunen founded his own captive flux cored-wire operation. This enabled Weld Mold the opportunity to develop complementary cored wires to the established die welding electrode product line. • In 1996, Weld Mold began producing cored wires in-house. During this same period, Weld Mold developed and patented a 1,000-amp welding “Manipulator” to fully utilize the potential of cored wires. Deposition rates of cored wires have progressed to 20-30 pounds per hour using the often-copied Manipulator. February 2012

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advertorial

Siempelkamp

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u ussia’s OAO Elektrostal placed an order with Siempelkamp for a closed-die forging press with 20,000 tons of pressing force to eenable the manufacture of nickel-based superalloys. The new press is the first one of this size with an integrated die-heating p ssystem. Other difficult-to-forge material (e.g., Inconel) can be processed d with ith this t press. Elektrostal will improve the real net output ratio of their own production and intends to produce more and more finished products of high-alloy steels in the future. The press, which is scheduled to be commissioned at the beginning of 2013, will allow the company to reach new markets. Elektrostal will manufacture high-temperature forgings with lengths of up to 1,200 mm (3.9 feet) and widths of up to 800 mm (2.6 feet) at a weight of up to 800 kg (0.9 tons) that are subject to increased thermal loads. These forgings can be used in aircraft turbines or power plants. Narrow tolerances have to be kept for these forgings. Because of this, Siempelkamp paid the most attention to detail in the design of the guiding elements. Elektrostal requested to equip the press with an integrated die-heating system since special conditions have to be maintained for the forging of superalloys. This system heats the tools to up to 800°C (1472°F), ensuring that the parts do not cool down. In addition, the forming speed can be specifically adapted to the process.

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As a result, near-net-shape parts and maximum reproducibility of the product quality are achieved. A special challenge in the design process was that the height of the press could only be 9 meters above the shop floor because of an overhead crane runway. Therefore, Siempelkamp designed a pull-down press. The moving crosshead is connected with four annular pistons by means of four columns. The pistons are positioned according to the cylinders arranged in the lower crosshead. The four columns as pre-stressed tierods serve the purpose of force transmission. The self-acting hydraulic adjustment of the press guide is disengaged from the elements of force transmission, thus avoiding reciprocal influence of force transmitting and guiding components. Siempelkamp offered an all-in-one solution (including hydraulics and electrics, die-heating system, loading and spraying robot, and forging manipulator) for the forging of complex component parts. Siempelkamp will also be in charge of the transport and assembly of the press. State-of-the-art simulation software ensures that the press not only achieves the required precision but also all ensures that all the components are reliably designed as to fatigue-critical structures to protect them from failure for the life of the press. The main component parts of the press – with a weight of approximately 260 tons – have already been cast in Krefeld, Germany, and are currently being machined. The press will be shipped this summer.

Maschinen- und Anlagenbau

Reliable, robust and precise Closed-die forging presses from Siempelkamp The merits of Siempelkamp closed-die forging presses at a glance: • Up to 400 MN press force • For all kind of products and different materials • Fast die change • Service-proven technology • Very high forging precision • Can be operated by a single person

The complete program of forging presses:

www.siempelkamp.com

Aubert-Duval, France

Siempelkamp Maschinen- und Anlagenbau Siempelkampstrasse 75 47803 Krefeld / Germany Tel.: +49 (0) 21 51/92-30 Fax: +49 (0) 21 51/92-56 04 E-mail: [email protected]

Siempelkamp‘s metal forming program

Plate forming

Pipe forming

Sheet metal forming

Hydroforming

advertorial

Superbolt Split-Nut Thrust Collar Solves Press Bolting Problems

O 0DNLQJGLI¿FXOWEROWLQJREVROHWHDOORYHUWKHZRUOG Superbolt® Multi-Jackbolt Tensioners provide a safe, IDVW HDV\EROWLQJDOWHUQDWLYH%HQH¿WVLQFOXGH ‡2QO\KDQGDLUWRROVUHTXLUHG ‡7LJKWHQVLQSXUHWHQVLRQ

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FREE DVD & CataloG!

www.superbolt.com

b btaining accurate and proper pre-stress on press tie-rods can be difficult, time consuming, costly or ti even dangerous. Removal can also be difficult using ev ttraditional diti l methods. Newly patented Superbolt® Multi-Jackbolt Split-Nut Thrust Collars (STCs) only require hand-held tools to achieve accurate pre-stress. With standard nuts, nicks in the thread, surface pressure on the threads and crossthreading can cause galling and seizing. STCs use a split thread and are much easier to install and remove, eliminating thread galling, and they are more tolerant of slight thread variations between nut and tie-rod.

PRODUCTS Inert Atmosphere Box Furnace No. 954 is an electrically heated 2000°F inert atmosphere heavy-duty box furnace from Grieve to be used for heat treating titanium. To heat the load, 57 kW are installed in nickel-chrome wire coils, supported by vacuumformed ceramic fibers. Workspace dimensions are 30 inches wide x 48 inches deep x 30 inches high. The oven’s 7-inch-thick insulated walls comprise 5 inches of 2300°F ceramic fiber and 2 inches of 1700°F ceramic fiber, while the 6.5-inch floor insulation comprises 4.5 inches of 2300°F firebrick and 2 inches of 1200°F block insulation. The unit is equipped with a roofmounted heat-resisting alloy recirculating fan powered by a 1-HP motor with V-belt drive, motor-operated vertical lift door, 100-pound-capacity alloy loading cart with cast alloy roller rails, 3.5-inch-diameter cast-alloy roller rail loading table with 4-inch-diamrollers and a rol eter cast iron rollers. This furnace also features atmosphere construction, which consists inert atm continuously welded outer shell, highof a con ttemperature door gasket, sealed heater tterminal boxes, inert atmosphere inlet, iinert atmosphere outlet and inert atmosphere flow meter. It also includes a m digital programming temperature cond ttroller, manual reset excess temperature ccontroller with separate contactors and a strip chart recorder. www.grieve.com w 36

Februar y 2012

Microporous Insulation

BTU-BLOCK microporous insulation from Thermal Ceramics is based on ultra-fine particles of fused silica, metal oxides and reinforcement fibers. This formulation creates a sub-micron pore structure, which limits the convection of air, conduction of heat and transmission of radiation. BTU-BLOCK is designed to provide ultra-low thermal properties throughout the temperature range. Benefits include reduced energy waste, reduced temperature variability, reduced installation thickness and reduced cold-face temperatures. www.thermalceramics.com

Combustion Safeguard

The Full Feature Protectofier from Protection Controls Inc. is for new installations, replacements and retrofits. It has been engineered to include all the safety and protection features of the original combustion safeguard with hard wiring, enclosed relays, encapsulated transformer, single terminal block, interchangeable components and high signal strength. In addition, the new Full Feature Protectofier has been designed to reach new levels of operating safety and control, with features including: proof of closure, proof of high fire purge, purge timing, proof of low fire start, ignition trial timing, pilot interrupt timing and eight status lights. www.protectioncontrolsinc.com

®

Parquench 90

As close to an ideal quenchant as technology can offer • Cooling rates from water-like to conventional oil

Parquench® 90 is a unique water based polymer quenchant. At 25% concentration and 120ºF, it provides all stages of quenching that approximate those exhibited by fast quench oils.

• High molecular weight, particularly suitable for forgings, high alloy steels and distortion prone work

Parquench® 90 has an unusually gentle cooling mechanism, reducing transformational stress thus preventing cracks and distortion.

• Non-toxic and Non-flammable with minimal environmental impact

Unlike glycol based products, Parquench® 90 releases no dangerous aldehyde or ketone fumes when burned, allowing for use as a timed or interrupted quench without hazard to workers or the environment.

• Water soluble at all temperatures and concentrations

Staffed by quenching experts, Heatbath®/Park Metallurgical is able to serve you quickly, competently and creatively.

Rely on the Experts… Rely on “Genuine” Park Products… Rely on Heatbath/Park Metallurgical

4 1 3 4 5 2 - 2 0 0 0 • w w w. h e a t b a t h . c o m Indian Orchard, MA • Detroit, MI • Chicago, IL ISO 9001: 2008 Certified

CLASSIFIED ADS

Classified Rates Per Column Inch: 1 time rate, $85.00 4 time rate, $80.00

Place you HELP WANTED ad in FORGE today – includes an online ad posting on FORGEmag.com and a job listing on the FORGE eWeekly Newsletter

Contact: Becky McClelland Phone: 412-306-4355 Fax: 248-502-1076 E-mail: [email protected] Becky can also be contacted regarding reprints SERVICES

Manufacturers Representatives Wanted Denton TSI/O’Brien & Gere provides comprehensive thermal solutions through the design, fabrication, installation, and commissioning of highquality systems for the heat treat, forging, and thermal industry. We are seeking Manufacturers Representatives for various locations throughout the United States, Canada and Mexico. Please submit credentials in conÀdence to: Mr. Joe Martin, National Sales Manager, by email to: [email protected]

EQUIPMENT FOR SALE

Hydraulic & Mechanical Presses Open and Closed Die, Custom 500 to 15,000 tons Repair, Upgrade, Rebuilding, FEA Parts, Service & Training Heavy Machining & Fabricating ISO 9001:2008 CertiÀed

Toll Free: 800-222-3608 Ph: 814-455-3941 • Fx: 814-456-4819

www.eriepress.com SERVICES

CAMPBELL PRESS & HAMMER REPAIR Repair, rebuild & replacement parts for presses; mechanical & hydraulic, hammers & upsetters. Used equipment & parts. Field welding & Machining. Worldwide service. Ph: 517-371-1034 • Fax: 517-371-2606 Website: www.campbellpress.com Email: Email: [email protected] [email protected]

The International Journal of Forging Business & Technology – All You Need to Know About the Forging Industry Becky McClelland (412) 306-4355 • [email protected] Kathy Pisano (412) 306-4357 • [email protected] Larry Pullman (888) 494-8480 • [email protected] Steve Roth (520) 742-0175 • [email protected] Patrick Connolly (44) 1-702-477341 • [email protected] Reed Miller Editor-in-Chief (412) 531-3370 • [email protected] Dean Peters Editor (330) 562-0709 • [email protected] Doug Glenn Publisher (412) 306-4351 • [email protected]

www.FORGEMAG.com

EQUIPMENT FOR SALE

AGOSTA INDUSTRIAL MACHINES A.I.M. Serving the Forging Industry William “Bill” Agosta

Appraisals, Liquidations, Auctions Your Used Forging Equipment & Machine Tool Broker

We Can Locate What You Need Or Sell Your Surplus Equipment Ph: (805) 382-6885; Fax: (805) 382-6886 E-mail: [email protected] www.agostamachines.com Member of American Society of Appraisers

February 2012

39

CLASSIFIED ADS 

Red Hot Forging Machinery Forging Manipulators

800 lb Taurus Robot Manipulator, VWDQG  RSHUDWH3%FRQWUROV5H 15t Morgan Rail BoundZLOOWDNH´GLD URXQGVH[WHQVLYHVSDUHV5H

Upsetters

8” Ajax, 24” stroke, DLUFOXWFK5H 10” 2000t Kramatorsk5H 12” (approx) 3150 ton Kramatorsk, ´VWURNHZHLJKVOEV5H

25t Herr Voss Electric Mobile, takes 36” dia ingots, Re:23888

Hydraulic Open Die Presses

5” National, DLUFOXWFKIRUJHWRQV ´VWURNH5H 7” Ajax Tong Feed,IXOO\DXWRPDWLFOLQH  QHZ¶V5H

Hydraulic Closed Die Presses

1500t Wood 4-Column  VLGHIUDPHSXVKGRZQ´VWURNH ´GD\OLJKWPRYLQJWDEOH5H 1500t Clearing 4-ColumnSXVKXS´ VWURNH´GD\OLJKWEUDQGQHZK\GUDXOLFV  HOHFWULFV([FHOOHQW5H 3500t Davy 4-ColumnSXVKGRZQ´ VWURNH´'/´EHWZHHQWKHFRO XPQV/5W0DQLSXODWRU5H

Ring Rolling Mills

80t Rail Bound´WRQJVRSHQLQJ ´WRQJVVLGHVKLIWUHEXLOW5H 10,000t Schloemann 4-column 30t Rail Bound´WRQJVRSHQLQJ´ IRUPLQJSUHVV´VWURNH5H WRQJVVLGHVKLIWUHEXLOW5H 2500t K.R. Wilson&ROXPQ5XEEHU3DG 20t Hyd. Rail Bound,´WRQJVRSHQLQJ 3UHVV´VWURNH´GD\OLJKW5H UHTXLUHVFRPSOHWHUHEXLOG5H 630t Schmid2UELWDOW\SH)RUJLQJ3UHVV ´VWURNH´HMHFWRU¶V5H Forging Hammers 1000t HPM #100,´VWURNH´ 1000 lb Chambersburg Ceco #4 Die 6+´GD\OLJKWEWZQEROVWHUV´[ )RUJHU´VWURNH5H ´EROVWHU5H 2,500 lb Chambersburg E-Ceco'URS ´VWURNH5DP)%´5H 800 tons Forging Die Steel 10,000 lb Erie Drop,´VWURNH5H 10,000 lb Chambersburg Drop´ in the form of used press VWURNH´EWZQJXLGHV5H forging dies, grades are MPM 10000 B Huta Zygmunt, 11,000 #2 & #3 FX-XTRA, Re:23983 .*PEORZHQHUJ\´VWN5H MPM 16000 B Huta Zygmunt, 17,500 .*PEORZHQHUJ\QHYHUXVHG5H Radial Forging Machines GOA-4000 Banning,PD[EORZHQHUJ\ 500 ton GFM SHP 10'LHWDNHVPP .*PZHLJKVWRQV5H GLDEDUVWURNHVPLQ5H

5.0 mtr (approx) x 26”/40” Wagner type Heavy Duty Radial/Axial capable of rolling 100,000 lbs rings, Re:23984 4.3” SKF EMB-110B+RW%HDULQJ5DFH ([SDQGLQJ/LQHZ,QG+HDWHU5H 8-5/8” SMS Wagner$XWRPDWHG5LQJ /LQHIXOO\UHEXLOW5H 52” Wagner type,YHUWLFDO´ULQJKHLJKW UDGLDOWRQV5H

560 ton GFM SHK 414'LHZ0DQGUHO Mechanical Forging Presses IRU+ROORZ&RPSRQHQWV5H 1300 t National Maxipres, ´VWURNH 800 ton GFM SHK 17'LHZ0DQGUHOIRU ´VKXWKHLJKWVSP5H +ROORZ&RPSRQHQWV5H 6000t Ajax´VWURNH´6+´[ 3200t SACK R800 4-Die, ´EHGVSP5H takes 680mm dia ingots, 4000t Clearing´VWURNHVSP´ min bar dia 100mm, electrics/ GD\OLJKW´[´EHG5H electronics fully upgaded to 2500t Erfurt PKXW 2500´VWURNH Siemens PLC S7 in 1998, Re:23575 ´[´EHG5H

TrueForge Global Machinery Corp. 0HUULFN5G6XLWH(5RFNYLOOH&HQWUH1