It is often possible to reduce a metal part's cost and
production time, while increasing quality, by keeping the
part's components to a minimum. If a part can be produced
as a single piece rather than two or three welded together,
unnecessary steps and expenses may be saved. By evaluating
finished prints or diagrams of customer parts, Scot Forge
has been able to offer many component reduction recommendations
which have saved time and costs for customers, while actually
increasing part strength. Below are just a few successful
cases.
Product/Application:
Previous Processing Problems:
Heat exchanger body for a
naval vessel
Material:
90/10 Copper Nickel
Part originally consisted of three components: one rolled and welded plate and two forged rings welded to the ends.
The quality of the forged rings was greater than the quality of the plate, making welding difficult.
Inclusions were present in the plate, requiring extensive weld repair and reinspection.
Weld areas required expensive X-ray testing.
Forging as the Solution:
Now, the part is made as a single forged piece with integral flanges.
Consistent quality is assured throughout the part, eliminating the instances of inclusions and making welding unnecessary.
Without welding, X-ray testing is no longer needed.
Product/Application:
Previous Processing Problems:
Cylinder rod for bucket on an off-road shovel
Material:
Low Alloy Steel
Previously the part was made from a cast head welded to a hot rolled bar.
Casting proved too weak for the application, resulting in shortened product life.
The need for welding lengthened process times.
In the field, excessive loads on the cast head caused part failures and required subsequent repairs.
Forging as the Solution:
Forging allowed the head and shaft to be produced as one part.
The strength and structural integrity of the forged material met demanding application requirements.
The elimination of welding has shortened part production time.
The forged head is able to withstand excessive loads without failure.
Product/Application:
Previous Processing Problems:
Mixer shaft for the pulp and paper industry
Material:
Stainless Steel
The former part was a rolled bar welded to a forged blank.
Heating
required during the welding process changed
the hardness and tensile properties in the
weld zone, making it necessary to re-heat
treat the part.
Cracking was occurring in the weld layer,
rework was needed, and there were many field
failures.
Forging as the Solution:
Forging
made it possible to produce the part as one
piece.
No welding or heating is required, so properties
have improved and extra steps have been eliminated.
Part strength has improved due to one-piece
construction and continuous grain flow, resulting
in less rework and fewer rejections.
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Successful Cases of Component Reduction
The quality of the forged rings was greater than the quality of the plate, making welding difficult.
