20th International Forgemasters Meeting - IFM 2017

3 production companies of Voestalpine Special Steel Division are involved in open die forging business , namly Böhler Edelstahl(Austria), Buderus Edelstahl(Germany) and Villares Metals(Brasil).Equipment, technology and typical products will be described . The transformation process to other product families due to changed global ODF markets will be discussed.

This paper describe the recent trends and development activity in the Japanese heavy open-die forging manufacture since the 19th International Forgemasters Meeting (IFM) held in Tokyo, Japan in 2014. In the three years since 2014, Japanese forgemasters have been developing new technologies aimed for high quality, cost reduction, greater productivity and efficiency. This paper focused on...

This paper updates remarkable changes in production and market trend, the status of major players, and development of new products and technologies of Korean open die forging industry since 19th IFM in Tokyo. Like many other countries, there have been heavy and intensive investments in major Korean forgemasters in early 2000’s when the global economy was booming up to its peak. But global...

Introduction to Chinese economy and heavy forging industry, in which will include power station, machine building, shipbuilding, matellurgy industry and the related industries. The presentation also will focus on what happened in forging equipment made in China, technology/process applied at the moment and management situation in China; especially will display some information concerning the...

This paper gives a brief update on manufacturing capabilities of Indian Forgemasters. Indian economy has seen significant growth since 2014. Positive movements are being witnessed in industrial sector as a result of initiatives like “Make in India” from Indian Government. Many big stalled projects have received green signal. A brief on facility addition/Upgradation resulted in extended...

The paper will inform about the economical and technical development of Ingot Manufacturers and Open die forging shops mainly associated with the VDEH-Forging-Committee and about the development of energy prices in the region. Highlights based on research and development of Universities will be presented. The paper will include also general information about the development of suppliers of...

Introduction of general Italian economy and forging industry with focus on changes occurred since the 19° IFM; since Tokyo, there have been 3 years of further stagnation but in spite of the resection, new investments have been completed in this time period. A review of recent developments of facilities and major changes in the Italian open die companies will be given. Presentation will...

Changes to the UK Forging Industry since the IFM 2014 in Japan will be described in full, including turnover, cost reduction, investment in plant and machinery and research & development. The future prospects of the business at Sheffield Forgemasters in the coming five years will be described.

There have been many changes in the North American open die forging industry since the 19th International Forgemasters Meeting (IFM) in Tokyo, Japan in 2014. By far, the most significant has been the severe decline in orders and shipments since 2014. On a shipped tonnage basis, shipments have declined each year since Tokyo and are projected to be at the lowest levels since the early 1990’s. ...

This paper gives a brief introduction of the open die forging industry in South America. It describes the capacities and forging equipment in the major companies. Also the effects of the economy in the open die segment will be reported. The open forging industry in South America has small influence in the global market, mainly due to the low demand when compared to others such as Europe, Asia...

The presentation will highlight the recent developments in the world of Forged Special Steels and remelted steels (nickel alloys, stainless steel, alloy tool steel and alloy steel) as well as will give an overview about end-user demand and structures of these special steels and also summarize the actual status of installations (forging presses and remelting units) on a global scale. The...

3.5%NiCrMoV steel has been widely used for generator rotor forgings for the purpose of obtaining high strength, toughness and magnetic permeability. Although the added alloy elements are important to achieve specified mechanical properties, reducing the amount of alloy elements is also important to contribute to natural resource savings and cost savings. In this study, the effects of Ni and Cr...

Extrusion tools, such as containers and stems, are expensive components and it is important to use the most suitable materials to gain a long service life. However, it has to be pointed out, that not only the applied materials determine the life time of these tools, but also melting and forging techniques, as well as heat treatment have an essential impact. Since many years, Bohler Special...

Offshore structure is the large installation to facilitate drilling, refining, saving, and producing oil and gas. Hence, offshore structure should maintain long term safety of structure against severe external environments such as storm waves and low temperature. Therefore, heavy thick steel plates required with high strength and toughness in low temperature have been needed as the engineering...

It has been a long time since the tragic accident in Fukoshima. Immediately all large projects went ‘on hold’ for an ‘X’ amount of time, since nuclear power was in question instantly. The skepticism proved to be wrong, since this world needs more energy soon. One efficient possibility is nuclear power, for which many large size forgings are needed. Large presses have been available already...

Currently ferritic heat resistant steels are mainly used for large industrial gas turbine disks because large disks made of ferritic heat resistant steels can be produced easily. On the other hand, it is well known that Ni based supperalloys such as Alloy706, Alloy718, Waspaloy, etc., on have much higher strength at elevated temperatures than ferritic heat resistant steels. Alloy718 has very...

Over decades Böhler Special Steel has been a full package supplier of customized high quality special steels and forgings. Böhler Special Steel fosters close relationships to plant manufacturers with the aim to provide products ahead of its time. This paper provides some results of our research activities to raise the operating temperatures of 9% Cr steels from 625 °C (1157 °F) to 650 °C (1202...

The SMX hydraulic radial forging machine from the SMS group is a market success world-wide. SMX hydraulic radial forging machines are to be found on practically every continent. The characteristics of a hydraulic radial forging machine are the high productivity combined with very close tolerances, irrespective of the material grade and dimensions of the feed stock and finished product. In many...

Our company always works on changing the casting to the forging. Particularly, we produce forging valves for thermal power generation. The materials support with low alloy steel, high Cr steel, stainless steel to a thermal condition widely. From the situation in the world, the demand for the thermal power generation increases recently. About the materials such as turbine casings, upsizing...

With the rapid development of economic, it is urgently need to develop coal-fired power generation technology of further increased value of steam parameters in China. National 700℃ USC coal-fired power generation technology innovation consortium has been founded to develop the 700℃ USC technology and key components of steam turbine in 2010. All the forgings used for 700℃ and higher steam...

Danieli Breda (DB) is one of his own business units, based in Milan, Italy, for over 50 years has been a leading in design, manufacture and supply of integrated plants for processing ferrous and non-ferrous metals in open die forging. In 2015 Danieli Breda started complete integrated Open Die Forging plant to produce rough axles for Railways. The Forging Complex, based on a high dynamic PFC...

The main technical parameters, design features, accuracy control, etc. of the ring rolling machine of RAW2500/1250-16000/3000 designed and manufactured by German SMS Group, to highlight the leading status in the world of this ring rolling machine. Introduce briefly on the application field and market demand of large rolling rings and technical advantage of this ring rolling machine on the...

In terms of increasing power demand in the world and a problem of global warming, high-efficient thermal power plant has been desired. A rise in steam temperature is an effective way for improvement of power generation efficiency, therefore a number of high temperature materials and components for USC/A-USC pressure turbine have been developed for many years. JSW began manufacturing...

Our company manufactures forged duplex and super duplex stainless steel products. These materials are called ASTM A182 F51, F53 and F55. These have high strength and high corrosion resistance. Super duplex stainless steels (SDSS) are by definition a duplex stainless steel with a pitting corrosion equivalent (PRE) > 40, where PRE = %Cr + 3.3x %Mo + 16x %N. So these are used injection pumps with...

It was described the development necessity of complete equipment for large forging hydraulic press. The general scheme of complete equipment consisting of 125MN double column open-die forging hydraulic press, and 1800kN/4000kN-m rail bound forging manipulator was proposed. A series of advanced design methods and key technologies were presented, such as digital prototype, co-simulation, visual...

The objective of this study is to develop the spent nuclear fuel shipping cask shell material and welding rods with high toughness at very low temperature. Recently, in Korea, The demand of shipping cask has been increased to transfer spent nuclear fuel and nuclear waste to an interim facility and store safely due to the limitation of the storage space inside nuclear power plant. The shipping...

The biggest challenges for forgemasters are currently the general economic situation and the increasing demands arising from the environmental protection. Thus an efficient process flow with the use of process heat is increasingly indispensable for the economic continuity. One possibility is the combination of forging and quenching, the so-called quenching from forging heat. For more than ten...

In recent years, as part of measures against global warming, utilization of renewable energy has been increasing to reduce CO2 emission. Especially, geothermal power generation, which can supply large scale power steadily, has been being developed around the world, and there is a growing demand for large rotor forgings for large scale geothermal power generation. Japan Casting & Forging...

The mono-bloc nozzle shell for CAP1400 RPV is a combined component of Vessel flange，Nozzle shell course, inlet and outlet nozzles, safety injection nozzles. The mono-bloc nozzle shell manufacturing is technically challenging for hot working technique due to its complex shape and large size. In order to realize the dream of eliminating both U-shaped and circular welding seams, a series of...

Pressure Vessel components, during manufacturing, undergo several heat Treatments that aim to confer the required properties on the entire equipment, including welds and base metal. Quality Heat Treatments (QHT) typically comprise of normalizing and tempering, or hardening and tempering, as per customer requirements. Usually, these QHTs are followed by Post weld heat treatments (PWHT). The...

L&T Special steels and heavy forgings private limited is India’s one of the largest forging plant with integrated steel melting facility which started its operation in 2012.It has got all associated facilities to deliver finish forged products up to 150 MT. This paper explains the process of establishing ultra-modern agitation system in quenching tank with specialized headers and nozzles. The...

This paper focuses on the extent to which modernization and technological advancement have been a crucial support for CHW Forge in its efforts to embrace modern forging techniques and compete at a global level. The demand of high quality forgings in India introduced us to a newly formed niche market where factors such as quality assurance, customer service and comprehensive...

A digital engineering system using finite element (FE) analysis was developed in order to optimized forging and rolling process for obtaining an adequate microstructure in large-scale forged and rolled products. For precise prediction of changes in microstructure during forging and rolling, the re-crystallization behavior should be investigate carefully. Ni-based super alloys are usually...

Low thermal expansion superalloys are thought to be candidates to reduce the clearance between some parts in turbo machines in order to improve the efficiency. Alloy903, Alloy909, HRA9291), etc. which were previously developed are well known as commercial low thermal expansion superalloys. The low thermal expansion properties of these alloys are obtained by the mechanism to control the thermal...

High Carbon Forged White Cast Iron Rolls are manufactured using a hot stage of as cast ingot till final forging shapes in order to avoid a brittle fracture of this material. The Forgings should be cooled for the first time to RT through a spheroidal heat treatment. During a continuous forging process carbides grow alone grain boundary and inside of grains. The special carbides are formed rod...

It has been widely focused because of its complex integral-structure and strict technical requirement since AP1000 main pipe appeared, which is made by 316LN stainless steel. After ten years of effort and exploring, excellent forging suppliers from all over the world agree that 316LN heavy forgings including AP1000 only can be formed by relatively simple solid forging technology though it...

Recently, Co-Al-W alloys with a new γ’ phase consisting of Co₃(Al,W) have been found. Since the Co-Al-W-based alloys show the γ/γ’ microstructure similar to the Ni-based superalloys and flow stress anomaly, it is expected that the Co₃(Al,W) strengthening Co-based superalloys would be able to be applied to higher temperature applications. However, the hot workability is...

The application of ultra high strength steels and advanced high strength steels at automobile industry is currently increasing for weight reduction and crash safety. The growing use of HSS results in decreasing tool life and productivity in manufacturing. The aim of this study is a development of high performance tool steel in hot work. Both the durability and high thermal conductivity are...

This article is concerned with the application of regenerative burner systems in heating plants with **batch-wise operation**. The use of regenerative burner heating systems in continuously operated plants in the steel and forging industries is well known and has been tested in practice over the years. Due to the enormous energy savings with correspondingly large power requirements, and the...

Identifying exact location to be repair for flaw rejected by radiography examination of large casting is important step to optimize production process, since repeated repair process consequent in longer production time and increased cost. Accuracy of flaw location measured by conventional ultrasonic technique is very dependent on inspector’s skill, consequently has considerable human error....

In recent years, global wind turbine market is increasing every year and wind turbine systems are getting larger to increase efficiency of power generation. With this trend, it is essential to manufacture lightweight and cost-effective main shafts which are main components of wind turbines. In this study, an attempt to design optimal hollow shaft and forge the component was performed. The...

The present paper gives a description of a new technological test for measuring friction coefficient using a closed die forging process. The test specimen is a cylinder of pre-defined dimensions. The result is a forging whose shape reflects the magnitude of the friction coefficient. The magnitude of the friction coefficient varies with the forging temperature and the lubricant used. The test...

Recently, we have developed an advanced skin pass mill back up roll (SPM BUR) which is one of the most essential elements in the manufacture of flat products of metals. In this paper, the alloy design concept and the excellent properties of the developed SPM BUR was introduced. In order to optimize chemical composition and manufacturing process, the following procedures were adopted. First,...

Abstract：The study on the multi-ram forging of the high temperature-pressure valve body is intended to meet the technical requirements for the valve body sustaining high steam parameters in thermal power generation units. The multi-ram forging of a 3-inch gate valve body was used as an example to demonstrate the features of the multi-ram forging, in which principles and methods of multi-ram...

Nowadays the production of 9-12% chromium steels is characterized by different metallurgical processes adjusted to the final application and customer requirements. Usually the primary melting is done in the EAF and the steel is further refined in the LF and VD/VOD respectively AOD process. In the production route a special focus lies on the casting and remelting technology. For casting the...

In vacuum ingot casting, molten steel stream is dropletized and degassed in the vacuum tank, since this process is one of the effective methods to obtain good internal quality and large ingots. There are cases that the large inclusions are observed in the vacuum casting ingots at the bottom part, which consist of SiO2, SiO2-MnO, and Al2O3-SiO2-MnO. As a result of the verification experiment...

Current requirements for internal combustion engines are becoming more and more demanding. Therefore, new generation of crankshafts needs to reduce in size and sustain higher loads. This dramatically increases the stresses in the components, making the fatigue strength enhancement a necessity. Sidenor understands that this improvement should arrive as a result of the combination of two...

Ni-base superalloy LTES700R turbine rotors for advanced-ultra supercritical (A-USC) power generation was produced, and their microstructure, tensile, impact, and creep properties were evaluated. 10-ton class rotor forging was successfully produced through the double melting technique, which is the vacuum induction melting (VIM) followed by the electroslag remelting (ESR), and free forging with...

Steel cleanliness is an important quality characteristic, which becomes more and more important since the invention of secondary metallurgy in the most steel mills. The question is: What are the main influencing parameters? This paper describes several influences on the macro cleanliness of big forging ingots. Some of them like the runner system refractory, the mould powder, ladle refractory...

Recently, the needs for eco-ships have been increasing from the viewpoint of the strengthened environmental regulations and the demands for improvement of fuel consumption. The engine design places importance on higher power in low revolution range, so that the stroke of engine becomes longer. As a result, the higher torsional vibration is subjected to the intermediate shafts. The torsional...

The most significant outcome of the European COST programs (1983 – 2009) was the development of creep resistant 9-10%-Cr-steels for 600°C and 620°C application temperature. COST FB2 steel alloyed with boron is currently the best available material for turbine shafts subjected to steam temperatures up to 620°C and meanwhile introduced in production for application in commercial power...

In 2012 Buderus Edelstahl decided to modernise its steel plant in Germany. Among others there was the request to implement a new ingot casting area to improve productivity, quality and workplace safety. The Advanced Teeming System ATS a high performance teeming system showing a high level of mechanisation and automisation of the casting process. At Buderus it is specially designed for casting...

Duplex stainless steels are in good combination with strength, ductility and corrosion resistance. For this reason, duplex stainless steels are considered as excellent choices for various industrial applications such as oil extraction, paper manufacturing and other chemical industries. From the industrial point of view, the hot deformation of these steels has drawn much attention due to cracks...

Ellwood Crankshaft Group (ECG), one of the world’s largest producers of industrial crankshafts, has invested in a modern horizontal multi-directional press to complement the CGF Loewy Press originally built in 1960. This new facility will produce monolithic medium speed engine crankshafts, industrial crankshafts, and a multitude of none crankshaft geometries. The new 310MN press operations...

Segregation, shrinkage porosity, and coarse dendrite are main problems in heavy forgings due to the ultra-slow solidification process in heavy ingot. Researchers and engineers have put a lot of effort on improving the solidification microstructure but harvest little. If we jump out of the mind of manufacturing heavy forging by heavy ingot, the solution may be found on the continuous slab,...

Dimensional inspection is essentially important to prove conformance to specifications of customers’ drawings in terms of quality assurance. Requirements concerning geometry of products are getting detailed and strict as represented by GPS (Geometrical Product Specifications) standards currently being developed by ISO/TC 213. Dimensional inspection by conventional measuring equipment such as...

During pressure test of a huge hydro power plant; embritteled weld material caused a catastrophic fracture of the closure head of a new penstock. Temper embrittlement (TE) in weldings of high strength steel type S 690.was identified as basic cause of theobserved failure. TE was caused by application of an unusual slow cooling rate during post weld heat treatment. A procedure, characterized by...

This study focuses on the development and comparison of standard and alternative methods to evaluate the cleanliness of hot work tool steels used for dies on a microscopic level. The steels subjected to this study are hot working tool steels produced by an electric arc furnace (EAF) and ladle furnace (LF). After re-melting by an electric slag (ESR) or a vacuum arc (VAR) furnace the forged or...

The remelting behavior of the hot-work tool steel X37CrMoV5-1 / H11, was investigated with several experimental melts on a lab-scale ESR-plant. The investigated parameters comprised a variation of the slag compositions and the use of a protective nitrogen atmosphere. Variations of the slag composition included slags with different contents of CaF2, CaO and Al2O3 as well as a variation of the...

Forging temperature is an important parameter to be defined in the forging process planning, because the final mechanical properties are directly influenced by this process temperature. In this study the AISI 4130 engineering steel, used for flexible tubes connectors in oil and gas industry, was investigated concerning the forging and heat treatment processes. Ingots up to 18 ton were forged...

BÖHLER EDELSTAHL is as part of the VOESTALPINE Special Steel Division, next to the production of Tooling Steel, High Speed Steel and Special Steel grades, a qualified and approved supplier for several renowned customers in the worldwide Energy- and Aviation-Industry. To fulfill the high requirements of our customers to the product quality, are, next to several destructive testing methods or...

The weight of ingots from Ni-Base alloys has steadily increased over the last years. One of the drivers was the development of advanced ultra supercritical fossil power plants requiring steam temperatures well above 630°C. Ni-Base alloys proved to have promising properties for steam temperatures of 700 °C and above. Whereas smaller parts are needed for the boiler side, some turbine designs...

The ultrasonic technique is the main non-destructive testing (NDT) method for the inspection of large forgings. With this technique, it is also possible to obtain information about microstructural features, which is very important because it gives the possibility to easily check the quality of processes during all the production cycle. In this paper, the relationship between some...

Japan Casting & Forging Corporation (hereafter JCFC) has developed an automated Ultrasonic Testing (UT) system for the improvement in reliability and applied it to the practical examinations on more than hundreds pieces of rotor forgings for steam and generator components in electric power plants since 2010. After that, further amelioration of the testing condition has been conducted through...

Because tool steels are widely employed in industrial as machining tools and dies. Excellent mechanical properties, such as hardness, toughness and strength, are the most important criteria in evaluating tool steels. As a coarse dendritic structure with bulk precipitates owing to segregation causing embrittlement in the interdendritic regions, grain refinement and the uniform distribution of...

Todays fashion Additive Manufactruring (AM) in the case of metal production integrates the achievements of 3D modeling and well-known methods of powder metallurgy (hereinafter - PM) in so-called printing. However, the very process of powders production brings a number of quality problems for PM product, as well as both the productivity and efficiency of the technological cycle of PM/AM ...

In this work, the effects of solution annealing and aging on an ESR Ni based superalloy are reported. The starting ingot has been hot worked as a rolled ring. The ring has been cut in several chunks, these were heat treated according an experimental design including trial solution annealing and aging at different temperatures and holding times. The microstructure, mechanical properties and...

Abstract Patriot Forge is a producer of 17-4 PH stainless steel components for the gas turbine and gas compression industry. To meet the demand of this high strength precipitation hardening steel in large forgings, Patriot has commissioned a new 5000 ton press. This alloy is open die forged from air melted, bottom poured ingots of different sizes. For the mentioned above application...

Commercial activity in regions of the world driving the need for large ST and GT generator equipment are showing soft market conditions. These combined with increased competition from equipment OEMs is driving significant pressure on product cost. Techniques such as should cost modeling and partnering with key suppliers and their respective suppliers to drive cost-out initiatives down the...

Evaluation of dimension and shape measurement during hot forging is an important process in open die forging. Correct dimension and shape evaluation reduces the risk of producing defective products and contributes to cost reduction, providing satisfactory yield. We have developed our own system for measuring hot dimension and shape during open die forging and put it into practical use. The...

Main structural frames of Danieli Breda forging presses are made by welded parts. The design of their fatigue life is based upon an expected service loadtable, and on recognized international standards that provide database for evaluation of fatigue performances of each type of welded joint. All the available recognised standards are based on experimental tests from civil structures, or from...

The ESR process has been established within the last decades as a mature, reliable and attractive production route for big forging ingots of more than 100 tons in weight. This material is further used for hollow or solid forgings in power generation industry. Advantages in solidification structure, mechanical properties and yield of the ingot shift the ESR process more and more in the focus of...

The Ultrasonic Examination of Austenitic Stainless Steel (A.S.S.) Forgings for critical application is a challenge, due to high thickness, isolated coarse grain structure and its complex configurations. To detect and characterize defects in these A.S.S. forgings, we at L&T Special Steels and Heavy Forgings (LTSSHF) have done study for ultrasonic examination technique based on stringent...

The potential consequences of failure within a nuclear reactor means components are designed with a high level of reliability and large margins for error. In a pressurised water reactor, this design criteria is most relevant to parts contained within the reactor coolant system. Amongst others, this includes a number of pressure vessels, each constructed from several forged sections. To ensure...

Nitrogen is needed for high Cr steel to improve corrosion-resistant and heat-resistant. In generally, nitrogen adjust method in ESR is addition of nitride briquette. However, in this method, nitride does not melt and might remain in an ESR ingot as inclusions. On the other hand, the addition of powder nitride isn’t suitable because yield for this method is too low. In this study, we...

Large forgings for power generation, ship shafts and plastic extrusion dies require large high quality ingots. In 2008, Ellwood Quality Steels (EQS) implemented a 2-ladle, interrupted pouring process to produce 70 Mton bottom poured ingots. Commissioning of the new 90 MN North American Forgemasters (NAF) open die press in early 2016 generated the need for much larger ingots. To produce ingots...

In the ESRR process, a T-shaped mold is used including a graphite ring that takes major amount of current through the mold. The standard ESR process can ideally control the solidification of ingot and produce homogenous structure with minimum defects. However, the melt rate of electrode is rather low that makes the whole process uneconomical especially to produce small ingot sizes. In...

Forgings, being usually one of the most critical components (like in power generation machinery), require intensive volumetric inspection to guarantee a sufficient lifetime. This is usually accomplished by manual or automated ultrasonic testing. We are reporting about a game changer in ultrasonic testing: Ultrasonic Computed Tomography uses analytics to reconstruct the volume (a linearized...

New AUT (automatic ultrasonic testing) system having capacity to inspect rotor forging of 300 metric ton was developed and successfully deployed to forged rotor manufacturing process. Mock-up test result and product examination experience using new AUT system shows that the system has detectability and sizing accuracy meeting industrial standards; The system can detect 1.6mm FBH (flat bottomed...

In recent years, the power generation industry has demanded forged parts of increasingly high quality to meet the requirements of increased operating temperatures and pressures. This has pushed metals suppliers to utilize Electro-slag Re-melt (ESR) technology to produce such large ingots. Single-phase, line frequency power supplies have traditionally been used to economically and reliably...

There is still an unbroken trend towards higher specifications and performance measures of metallic components and assemblies, no matter how they are processed.There are two major trends forcing engineers from all relevant disciplines–to continuously reach and exceed known limits of existing approaches.The lightweight idea has been establishing as an everyday business task since the last five...

"A mathematical model for hydrogen degassing of molten steel in an argon-stirred ladle has been developed and implemented using ANSYS Fluent. Hydrogen removal has been predicted for a range of argon injection flowrates and validated with industrial data from a full-scale vacuum arc degasser. The effect of nozzle arrangement, ladle aspect ratio and the physical properties of the slag layer on...

Ultrasonic Nondestructive Testing (UT-NDT) is the only technique that allows the inspection of the entire volume of large forgings. For this reason, improvements of the UT-NDT sensitivity are a key goal for the forging industry. Pulse-Echo (PuE) is the reference method for which all the Standards and evaluation procedures have been developed so far, and it is effective in most of the...

The use of hollow ingot technology presents may advantages in safety critical applications such as nuclear island components. Although not new technology to Sheffield Forgemasters International Ltd. (SFIL), in order to implement large-scale hollow ingots in the conservative nuclear power market, the material behaviour must be proven to be equivalent to or better than material from...

When rolling rings with high-precision and a high speed, it is crucial to accurately determine the dimensions of the ring. The conventional method for measuring this was to push a measuring device in direct contact with the ring. Recently ring measurement is shifting from mechanical measuring with a measuring cylinder towards non-contact measurement methods like laser sensors. However, there...

Taewoong utilized continuous cast facility consists of EAF(Electric Arc Furnace), LF(Ladle Furnace), VD(Vacuum Degassing), VOD(Vacuum Oxygen Decarburization) and CC(Continuous Casting) to manufacture Ø1,000 grade large diameter round bloom. Characteristics of utilized facility were analyzed and relationship between casting process parameters and casting defects were derived. Hot forging...

Ring rolling is an incremental bulk metal forming process for the production of seamless rings up to 10 m in outer diameter and up to 4 m in height. In ring rolling, the process layout is of high importance for the reduction of material waste and chipping. Simultaneously, waste due to product errors e.g. form errors, cracks and coarse grains has to be prevented. Nowadays, the waste due to...

It is generally accepted that hydrogen is only a contributor to failure when in its monatomic form. As a result, an important measurement in determining whether hydrogen damage is present in a material is a measure of diffusible (mobile) hydrogen. This measurement cannot currently be conducted either quickly enough or reliably enough to be used during industrial steel manufacturing....

Active thermography, using electromagnetic excitation, is a non-contacting, non-destructive evaluation method with a wide range of applications. It allows detecting inhomogenities, like cracks, at or close to the surface of metallic components fast and reliable utilizing infrared imaging. Electric current can be used in two ways for thermography: In induction thermography a current is coupled...

316LN stainless steel is selected as the material for forgings in the nuclear power plant owing to its better mechanical properties and excellent corrosion resistance. In this paper, the strain stress behavior and microstructure evolution of nuclear grade 316LN austenitic stainless steel under different conditions were investigated by several thermal simulation compression tests. Based on the...

Forged high performance parts require efficient and exact quality assurance methods such as ultrasonic (UT) inspection. Increasing requirements on NDE from OEMs are leading to change from manual UT to automated inspection systems at the forges. Ellwood City Forge (USA) is producing quality forged parts for different industrial use, including turbine disks and rings for various power...

A non-neglecting percentage of the final quality of forged pieces is originally depending on the ingot parts from which they are made. It is well known that the ingot defects like hot tears or cracks are rooted at the first beginning of the solid shell birth. Damages result from the competition between hydrostatic pressure within the turbulent flow of the liquid zone and the solidifying skin...

The paper describes an analysis of the main topics of all IFM-Conferences from the 1st Meeting in London 1954 to Graz 2017. The result of the analysis of 1152 papers is presented. The focus of these main topics will be analyzed in more detail. This analysis will highlight a trend where it is necessary to place the focus of research and development in future, namely on the...

In the forging sector, during the open die forging process, dimensional checks are necessary to guarantee that the final component is extracted from the forged envelope. Usually, the forged envelope needs to be enough to accommodate surface features typically associated with forging, whilst not being overly generous, as this decreases yield whilst increasing cost. Typically, forgings are...

Intelligent Manufacturing (IM) technology belongs to the advanced & the new production technologies. Recent years, China government published several policies to support the discrete production type industry including open die forging industry to develop IM. However, there is few of the open die forging plants responding actively. Comparison with the volume production type industry, the open...

A　forging pass schedule affects a closing behavior of internal void in ingots. To evaluate a void consolidation behavior, the parameter Q-value, which is calculated from the hydrostatic stress and the equivalent strain, is reasonable. The recent progress of forging simulation technology makes Q-value calculation easier. A forging pass schedule has been decided by forging ratio. It only...

Michael A. Kamnikar1, John Cain2 and John R. Paules3 1 North American Forgemasters, New Castle, PA, USA e-mail: mkamnikar@naforgemasters.com, Web page: www.naforgemasters.com 2 Scot Forge, Spring Grove, IL, USA e-mail: jcain@scotforge.com, Web page: www.scotforge.com 3Ellwood Group, Inc., Ellwood City, PA, USA e-mail: jpaules@elwd.com, Web page: www.ellwoodgroup.com North American...

**Points of Classification and a Short Abstract** The target was to analyze the complete forging process from raw material to finished forged parts. The presentation is based on a best practice example considering growing forging sources from Asia. In a first step, all relevant parameters for the whole process needed to be defined. This analysis phase was done at international suppliers...

FUJI OOZX Inc. (OOZX), who are pursuing their global growth in the field of automobile engine valve production, further improving quality of the valves, had installed the world's state-of-the-art Multi-functional Hydraulic Press that made it possible to make wide variety of forging. This report describes the characteristics of the state-of-the-art equipment and of the effect of quality...

It is important to deliver integrated forgings for elimination of in-service-inspection and improvement of quality of large forgings. Integrated forgings could be manufactured by integration of head with various nozzles by removing weld seams which is located between two parts. This manufacturing technology should be adequately designed to ensure accurate final dimension, internal material...

11/4Cr- ½ Mo steels are designed for critical applications in heavy wall pressure vessels operating below 441°C. API recommended practice: API 934-C states that beyond a thickness of 100 mm, this material shows difficulty in meeting sub-zero impact toughness and percentage shear requirements at the mid-thickness, which is required by API 934 – C. API recommends the use of a higher alloyed...

We reinforced steel plants newly and started the production of the large steel ingot of 100 tons in December, 2016. (The maximum size of the conventional steel ingot was approximately 75 tons.) The larger steel ingots manufactured in the bottom casting, and the larger ingots were forged in the 8000 tons press machine. The method to produce the high quality of steel ingot was studied by using...

Production of calibrated rolls for steel industry in the Forge Division began in 70’s and have lasted incessantly. Rolls made of forged steel are able to work in extreme conditions and can transfer heavy loads. In the past few years technology of roll production has changed in Forge Division of CELSA Huta Ostrowiec. Now we are able to offer rolls with improved properties. We produced...

A new type of stroke-limited forging drive system was developed by GFM for its radial forging machines. As opposed to eccentric shaft machines this new drive creates two strokes per shaft revolution. Hence the stroke rates are doubled and allow for distinctive higher throughput and tighter tolerances. A prototype with eight synchronously working tools was built in house for proving the concept...

Presented approach to simulation of the ring (or wheel) rolling technology includes modeling of the whole sequence of technological operations starting from upsetting of an ingot, then forging a blank, piercing it and finally rolling it in a stand and heat treatment. The specific feature of a ring rolling process that makes its simulation so difficult is related to big number of rotations...

Prior to further processing of semi-finished steel and special alloy products, it must be ensured that the surface of the work pieces is free from scale and flaws. In addition to that, these products also need to be cut and the cut surface needs to be free from heavy burr and surface hardening. For both applications, even for increasingly large product dimensions and regardless if the...

Electroslag Remelting (ESR) furnaces with electrode exchange techniques offer the possibility to produce large-sized ingots with homogenous, dense structures, high cleanliness levels and desired mechanical properties for high quality materials. ESR units that form one large ingot from multiple electrodes require electrode exchange techniques and typically utilize an ingot withdrawal system....

**ABSTRACT** In recent years, regenerative burner is adopted to improve the combustion efficiency for heating furnaces. Typically, the heat storage media for this burner have the shape of ball or honeycomb, and are made from alumina or cordierite. TYK focuses on Silicon Carbide (SiC) for heat storage media. It is because SiC has lower thermal expansion, higher strength, higher thermal...

Operation of four-die forging devices (FDFD) under various operational conditions and on various hydraulic presses, which differ in their design concepts and degree of automation, showed that in every application case an individual approach should be used to select optimized design concept and forging technology depending upon actual production objectives. With a view of above, introduced in...

In order to ensure closure of a voids in a large steel ingot and obtain a good internal quality, it is necessary to establish the quantitative evaluation method for void closure in multi-pass forging. Although many evaluation formulas with equivalent strain, εeq, have been proposed as evaluation methods for void closure in single-pass forging, there is few reports of detailed study on it in...

Validating new materials and heat treatments for large forgings is often a long and iterative process, due to uncertainty of through thickness variations of microstructure and mechanical properties. Finite element modelling can provide insight into the variables that control this variation, however material characterisations remain the province of small scale experimental simulations, and/or...

In the production of the large forgings, a reduction in exhaust carbondioxide and nitrogenoxide is a key issue from the viewpoint of the environmental protection, and a decrease in fuel consumption of gas combustion type forging furnaces is therefore in highly demand. Japan Casting & forging Corporation (JCFC) has introduced new regenerative burners for the furnaces since 1999. In a furnace...

Continuous demand for improvements in the forging industry makes life-cycle-cost of industrial equipment an essential focus for the plant operator. As the forging process by nature is an extremely energy consuming process, one of the biggest parts of the operating costs are energy costs. In conventional hydraulic press drives for forging presses the pumps are running on fixed speed and the...

Monoblock LP (Low Pressure) rotor shaft becomes larger with increasing the capacity and the efficiency of nuclear power plants. In addition, the size of ingot is required over 600 ton. With increasing the size of ingot, the high internal quality is very important to minimize the segregation of chemical compositions, non-metallic inclusions, micro porosities and so on. Therefore, to meet these...

A key point to satisfaction in the industrial sector is energy savings as well as maintenance friendliness as far as vital part of a production is concerned. DANGO & DIENENTHAL has proven over decades to be ahead in this field. All machinery is customized and of modular design. This ensures a most compact and flexible solution, which in turn generates the least-expensive operating cost in the...

High temperature furnaces are an integral part of the open die forging process and a sizable portion of capital expense for a new press project. What is most important to the production managers, finance department, HSE managers, and maintenance group must be considered. Conflicting furnace attributes such as energy efficiency, production, emissions and temperature uniformity make these...

High pace rate progressive reduction is the core of traditional radial forging process. Design based on eccentric shafts or crankshafts with mechanical synchronization of the 4 hammers has no equal in terms of precision, rigidity, speed. However, each single deformation is short and typically does not allow the plastic field to reach the center of the work piece. Therefore, unless hollow...

Osaka Steel Works(OSW) manufactures the high-chromium steel products,e.g. pipe used in power plant, which are forged in open-die 3,000Ton vertical press. In OSW, forging temperature must be applied to 1250℃ or higher for being loadable in press and deformable for high-chromium steel. NDT were carried out in shipping inspection, although, in some case the defects were found in the products. So...

During the solidification of large ingots, fluid flow and the sedimentation of solid grains can lead to the development of inhomogeneities in chemistry over length scales of a metre or more. This chemical segregation, referred to as macrosegregation, must be understood by manufacturers if they are to produce components that are as homogeneous as possible. This paper explores our current...

Presented in this paper is a comparative analysis performed by means of technology simulation based on FEM method using DEFORM 3D tool. The following processes were analyzed: - forging on a hydraulic press between two dies according to conventional technology; - forging on a four-die radial forging machine (RFM); - forging on a forging press in a four-die forging device (FDFD)...

For many years Saarschmiede has focused on the development of large remelted Ni-based alloy forgings typically used for research and development projects in the field of the power generation industry and for the nuclear industry too. Across these industrial sectors, there is a drive towards larger forgings with consistent mechanical properties, low levels of chemical segregation, more complex...

Danieli’s mission is to provide the most technologically advanced Forging plants with new installation and with appropriate modernization using parts of existing plants. Increase, the capacity 'of the existing plant is one of the goals more' challengers for the Danieli Team. In this direction such as the most challenging is surely the opportunity 'to increase in existing plants: -1) ...

Anenergy efficient methodcalled Forging Solidifying Metal (FSM) in two phase region, which applied for manufacturing special steel was proposed based on semi-solid forming technology (SSF).To verify its feasibility, the effects of deformation temperature and deformation methodson the microstructure of H13 were investigated experimentally.The bulky dendrites structure and shrinkage cavities can...

The open-die forging unit consists of a respective forging press with hydraulic drive and one or two forging manipulators. A properly conceived manipulator increases productivity and quality in the sphere of open-die forging significantly. In addition to the proces of manipulation with ingot and forging throughout the forging operation, the manipulators are included in the integrated forging...

Four Die Forging Device (4DFD) is a known equipment to improve the productivity at the forging shop when compared with conventional forging process. Despite the improvement of productivity it is supposed that the quality should be at least similar. In fact, previous finite element simulation showed the forging process using 4DFD produces less effective strain in the forged bar due to less...

Continuous development in materials, processing and joining technology opens up new possibilities for the application and optimization of forged parts with more complex structures. In particular, extrusion processes and the use of higher-alloyed, or micro-alloyed steels, which are becoming increasingly important in the production of high-quality forgings, present challenges for the...

Upsetting is a basic operation of greatest importance, which is commonly used in heavy forging process. Slowness in research on upsetting impeded the development of technologies for heavy forgings making. Upsetting deformation is determined by the billet’s internal velocity fields (or displacement fields), therefore, the key to the research on the upsetting deformation is to get its true...

The hot ring rolling process with as-forged ring-shaped billets is designed conventionally for forming the accurate size and configuration of all kinds of ring components. However, when the ring-shaped billet is prepared by casting, the hot ring rolling process have be designed not only to form the accurate size and shape of ring parts but also to transform as-cast microstructures into the...

There are three important points in heat treatment: agitation – agitation – agitation ! However, the speed in handling plays an important role in such a plant as well. The necessity to change the product range and sometimes also the layout of a plant some times, generated an idea of a movable tank in a self supporting structure with an integrated handling system to quench the material in less...

a marine crankshaft is the key component for large ships’ power transmission. One of the critical techniques for the marine crankshaft manufacturing is the forging of its crankthrows. Existing forging techniques for marine crankthrows have limitations such as low material utilization, complex operations with multiple heatings, discontinuous material flowlines and cumbersome removal from dies....

The trend of Industry 4.0 shows itself as the collaboration of multidisciplinary technologies to increase efficiency and effectiveness. The cooperative use of measuring, big-data handling, modelling and controlling technologies in a production plant is usually not trivial and requires specific approaches and adaptations. This paper presents a conceptual basis concerning the comprehensive...

Danieli’s mission is to provide the most technologically advanced Forging plants available in terms of machinery and production processes in order to meet market challenges. The value in Danieli FORGING TOOLS technology is to enable the processing of materials at technological limits, execute automatic forging sequences, guarantee process repeatability, higher productivity and ultimately...

Open-die forging is an incremental bulk metal forming process, which is mainly used for the production of long and straight workpieces with simple geometries. The production of complex geometries usually requires additional manufacturing steps or can only be realised by a high amount of machining. A new and innovative manufacturing approach is based on the idea to realise the production of...

Various routes for manufacturing of high quality steel grades at small to medium batch sizes are examined. Special attention is paid to process features with respect to refining flexibility and production costs. It will be shown how the combination of cost effective melting furnaces with subsequently performed refining processes in a Vacuum Induction Degassing (VID) unit provide means to...

The energy efficiency in forging technology is an ongoing task for the forging industry due to global challenges (resource availability, environmental impact), legislative decrees (eco-design of products) and national projects (energy transition). An eco-design of energy-using products is required as described in the European directive 2009/125/EC. As continuously rising energy prices put a...

Quality control of large forgings is a manufacturing process by which entities review the quality of all factors involved in production. On one hand, this paper briefly describes the research status of large forgings with the common flaws and their solutions, such as flaw segregation, inclusions & harmful elements, shrinkage cavity & porosity, bubble, discontinuities(crack), over-heating due...

Intelligent Manufacturing (IM) technology belongs to the advanced & the new production technologies. Recent years, China government published several policies to support the discrete production type industry including open die forging industry to develop IM. However, there is few of the open die forging plants responding actively. Comparison with the volume production type industry, the open...