20th International Forgemasters Meeting - IFM 2017

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...