Scot Forge, a leader in open die and rolled ring forging, reports that its unique forging component reduction process saves time and costs while increasing part strength and quality, compared to welding two or more components together. By producing a part as a single forged piece rather than a multi-part weldment, unnecessary steps and potential problems with weld seams are eliminated.

Scot Forge's ability to produce uniquely shaped parts as single component forgings provides a variety of advantages compared to weldments created from plate, castings, rolled bars, and other parts. Forging's continuous directional grain flow and structural strength provides improved mechanical properties and eliminates internal voids, ensuring optimum part performance under field service conditions. Without welds, the resulting parts have no weak areas which could cause part rejections or part failures. The elimination of the welding step also shortens production time and eliminates costs associated with the welding process itself and possible inspection and rework costs that may arise.

Scot Forge has forged many high quality parts utilizing the component reduction process. The process allowed them to produce a heat exchanger body as one part with integral flanges, rather than a previously produced rolled and welded plate with forged rings welded to the ends. This solved problems with inclusions, weld repairs, and X-ray testing. In another example, Scot Forge replaced a cylinder rod made from a cast head welded to a hot rolled bar, by providing a single forging. The replacement prevented previous problems with short product life, long process times, and part failures. Spindles, shafts, and other products can also be produced with component reduction.