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Properties
Forged steel is often used in weapons, thanks to its strength and durability.
Forging steel is a metal-working process which involves the use of hammering or pressing techniques to alter the steel’s shape, followed by heat treatment. This method produces in the steel a number of properties which distinguish it from other treatments of this metal, for example casting, where liquid metal is poured into a mold and then left to solidify.
Strong and Durable
Steel forgings have a generally higher strength and are typically tougher than steel processed in other fashions. The steel is less likely to shatter on contact with other objects for example, making forged steel highly suitable for items such as swords. This increased strength and durability is a result of the way in which the steel is forced into shape — by pressing or by hammering — during the forging process. The steel’s grain is stretched by this process, and ends up aligned in one direction, as opposed to being random. Following the pressing or hammering, the forging is cooled in water or oil. By the end of the process, the steel is stronger than it would have been had it been cast, for example.
Anisotropic
A steel forging’s strength isn’t consistent all the way through; instead, steel forgings are anisotropic, which means when the metal is worked on and deformation occurs, the steel’s strength is greatest in the direction of the resulting grain flow. This results in steel forgings which are strongest along their longitudinal axis, while in other directions, the forging will be weaker. This differs from steel castings, which are isotropic and therefore have almost identical properties in all directions.
Consistency Between Forgings
Since the process of forging is controlled and deliberate, with each forging undergoing the same steps, it’s typically possible to ensure a consistent material over the course of many different forgings. This is in contrast to cast steel, which is more random in nature due to the processes used.
Limit On Size
During the forging process, it’s more difficult to shape the metal, since forging occurs while the steel is still solid, unlike in casting where the metal has been reduced to its liquid form as part of the process. Since the metallurgist working with the steel will have more difficulty altering the metal’s shape, there’s a limit on the size and the thickness of the steel which can be successfully forged. The larger the metal section being worked on, the harder it is to forge.
Forged steel is the use of a variety of forging material produced and forgings, forgings castings higher quality than can withstand large impact force, effect, ductility, toughness and other aspects of mechanical properties are better than steel castings high, so whatever some important machine parts should be used forgings.
The characteristics of forged steel such as strength and resistance benefit every industry from automotive to agricultural machinery and manufacturing.
Steel forgings serve as pipe fittings in the oil and gas industry whereas as pulleys and gear wheels in the automotive industry.
The aircraft industry benefits from the strength of forged steel in their fasteners and airframe members.
Because of their low cost, wide accessibility, ease of handling, and excellent mechanical qualities, forged steel preparations are widely used in steel manufacture. Heat and mechanical medications are generally more susceptible to amalgam preparations than carbon preparations. Amassing cycles, such as welding, darting, or riveting, are used to quickly make forged pieces. The determination of a forged can regularly dispose of the requirement for gatherings. Much of the time, forgings are prepared for use without surface molding or machining. The manufactured surface is fit for plating, cleaning, painting, or treatment with beautifying or defensive coatings.
The difference between casting & forging
Casting is the process where metal is heated until molten. While in the molten or liquid state it is poured into a mold or vessel to create a desired shape. Forging is the application of thermal and mechanical energy to steel billets or ingots to cause the material to change shape while in a solid state.
We use castings for a wide range of wearparts and components that are too large, complicated, intricate or otherwise unsuitable for the forging process. We can forge parts up to 50kgs but the sheer energy required to forge larger items make casting a much more viable alternative.
We currently cast mining and earthmoving components to 580 kg. We can cast up to 3000 kg if required. Manganese work hardening screens are one of our specialities. We have found that by carefully choosing alloys and applying proven methods of heat treatment, we can produce castings of high quality, strength and wearability. The casting process better lends itself to making parts where internal cavities are required.
The advantages of casting include:
- No real upper size limit in casting weight
- Large range of alloy choices
As forgings remain solid, custom alloys are far more difficult to get into production whereas with casting, alloys including Chrome, Nickel and Moly can be added at the molten stage.
- Tooling is often less expensive than forge dies
- Smaller production “runs” required
- Complicated/complex parts are no problem
- For general GET as well as large and complex components – casting is a fantastic method of manufacture.
Why use forgings?
Forging offers uniformity of composition and structure. Forging results in metallurgical recrystalisation and grain
refinement as a result of the thermal cycle and deformation process. This strengthens the resulting steel product particularly in terms of impact and shear strength.
Forged steel is generally stronger and more reliable than castings and plate steel due to the fact that the grain flows of the steel are altered, conforming to the shape of the part.
The advantages of forging include:
- Generally tougher than alternatives
- Will handle impact better than castings
- The nature of forging excludes the occurence of porosity, shrinkage, cavities and cold pour issues.
The tight grain structure of forgings making it mechanically strong. There is less need for expensive alloys to attain high strength components.
The tight grain structure offers great wear resistance without the need to make products “superhard” We have found that, on a blank HRC 38-42 forged grinder insert wear/wash is about the same as a high alloy HRC 46-50 cast grinder insert. The difference being a HRC 46-50 casting does not have the ductility to handle high impact grinding.
Materials
Forged steel fittings are very high quality and are meant to have higher yields to high pressures.
- Standard Grades: Carbon, Stainless Steel, Chrome Moly, High Yield, Low Temperature, Aluminum
- Special Grades: Inconel, Incoloy, Hastelloy, Titanium
- Sizes: 1/8” to 4”
- Pressures: 2000#, 3000#, 6000# – special 9000# and up
On forged steel fittings, it is important to have uniformity of the walls of the fitting, as well as crisp threading to prevent stoppage in flow through the system.
| Material | Grade |
|---|---|
| Stainless Steel | 304/304L, 316/316L, 304H, 316H, 309, 310S, 317L, 321/321H, 347/347H, 904L, DUPLEX 2205 / SUPER DUPLEX 2507 |
| Carbon Steel | A105 |
| Chrome Moly | F5, F9, F11, F12, F22, F91 |
| Nickel Alloys | Alloy 20, 200, 201, 400, 600, 625, 800H/HT, 825, 254SMO, AL6XN, C276, C22, B3, HAST-X |
Manufactured by a series of compression under an extremely high pressure, steel forgings normally have less surface porosity, finer grain structure, higher tensile strength, better fatigue life/strength, and greater ductility than any other steel processing.
Classifications
Forging is one of metal pressure processing methods, referring to that use pressure to change the shape of metals so that can acquire forging pieces having mechanical property, shapes and dimensions.
The followings are the classifications of forging.
1. Hammer smith forging
The pattern of hammer forging is the same as blacksmithing. The work pieces are heated to the forging temperature, then, put between hammer flattener and drill plate for further forging. Small pieces can be made by hand, called as blacksmithing. Larger pieces need steam hammer. The work pieces are put between drill plate and hammer flattener. Structure of steam hammer is determined by forging capacity. Light one is single stand while heavy one is double stands.
2. Drop hammer forging
The difference between drop hammer forging and flat forging is that there is a mold cavity on hammer used for drop hammer forging. Work pieces suffer from two aspects of pressure or impact force in mold cavity, plastic deforming according to the shape of mold cavity. To ensure sufficient flowing of metal, forging is usually divided into several levels. Transformation in every level is gradual, advantageous for controlling flowing direction. Quantity of level depends on shape and dimension of forging pieces, forgeability of metal and precision of work piece.
3. Press forging
Press forging is a forging method that metal is extruded and formed inside mold under the pressure at a low speed. Due to metal stressed for a long time, extrusion is not only carried out on the surface of forging piece, but also carried out in center. Therefore, for even inside and outside, the quality of products is also better than that of drop hammer forging.
Forging used for manufacturing the shell of cellphone can reduce time of CNC effectively, having low relative cost. Moreover, aluminum alloy whose aluminum content exceeds 95% can be chosen for anodic oxidation.
Manufacturing process:
- Firstly, acquire structural parts of cellphone having higher thickness;
- Then, mill off the unnecessary parts through CNC, acquiring integrated structural members combining metal and plastic;
- Treat surface with anodic oxidation;
- Lastly, glue antenna cover.
4. Upset forging
Upset forging means that forge one of ends of an even long rod. Clamp the rod in the mold; heat one of end to high temperature. Force the end along the axial direction, upsetting and forming.
5. Roll forging
Use two round rollers (25%~75% reduction of diameter; the other part can be cut into groove shape based on requirements). Put rod into the two rollers and tight it, then, continue rotating, roll compacting the rod, reducing diameter and pushing it forward; when the rollers rotate to opening position again, withdraw the rod back to original position for the next cycle rolling, or send the rod to another grove for other construction.
Grades
Forged Fittings are widely used to connect pumps, valves, pipes, and many other equipment. These fitting are mainly available in two types, such as threaded fittings, which connect a pipe with fittings by screwing, and socket weld fittings, which connect a pipe with fillet welds. These forged fittings are widely available in many materials and grades.
Stainless Steel
This is one of the perfect materials to use for forged fittings. Stainless steel is available in different standards such as ASTM, ASME A, and SA 182. Various grades of Stainless Steel material such as 304, 304L, 3034H, 309S, 309H, 309H, 316, 316H, 316L, 316LN, 310S, 310H, 317,317L, 321, 321H, 347, 347H and 904L. All these grades are suitable for the forging process. Also, these grades are making forged fittings perfect to use in all complex and general applications of various industrial sectors.
Duplex and Super Duplex Steel
This material is also preferred for the forging process to fabricate different products. Duplex steel and super duplex steel have different grades, such as F51, F53, F55, F44, F45, F60, and F61. All these grades are available in standards like ASTM and ASME A.
Nickel alloy
Nickel alloy is used to manufacture forged fittings, which is available in ASTM, ASME SB 564, 160, and 472 standards. Nickel alloy is available in many grades such as UNS 2200 (Nickel 200), UNS 8825 (Inconel 825), UNS 4400 (Monel 400), UNS 6600 (Inconel 600), UNS 6625 (Inconel 625), UNS 6601 (Inconel 601), UNS 10276 (Hastelloy C 276), and UNS 2201 (Nickel 201). All these grades are ideal for forged fittings and make them able to sustain a certain amount of load in industrial applications.
Copper alloy
The copper alloy has many grades such as UNS No C92200, UNS No 70600, 71500, C 70600 (Cu-Ni 90/10), UNS No C 83600, C 71500 (Cu- Ni 70/30), UNS No C 10100, C 10200, C 10800, C 10300, C 12000, and C 12200. All these grades of Copper alloy are used for forged fittings, and all these available in many standards such as ASTM, ASME SB 151, 152, 61, and 62.
Carbon Steel
Carbon steel is one of the widely used materials for forged fittings. This alloy is available in different standards such as ASTM 105, A694, A350 LF2, and A350 LF3. Carbon steel has various grades, such as F42, F46, F60, F65, F52, F56, and F70. Carbon steel grades are making forged fittings durable and sustainable for different industries.
Alloy Steel
Alloy steel is available in only one standard, i.e., ASTM A182. This material has grades like F1, F9, F5, F11, F22, and F91. All these grades are suitable to use in forged fitting manufacturing as per the industrial requirements.
Brass
Brass is also used for forged fitting manufacturing. This material is available in different grades, such as Brass CA 360, CA 345, CA 377, SAE J531, SAE J530, and ASA. All these grades are widely available in the market and making forged fittings suitable to use in different industrial sectors.