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Successful Cases of
Uniquely Shaped Forgings
What can you do when you require a uniquely shaped part that must have high strength properties? While casting is commonly considered for unusually shaped parts, it cannot meet high strength requirements in many applications because of its lack of directional grain flow, and presence of inclusions. But there is a solution which companies sometimes overlook: forging. Today's forging process, combined with secondary processes such as torch cutting, can accommodate unique shape needs and provide cost efficiencies, while imparting the exceptional strength it is known for. Examples are described in the cases below.

Product/Application:
Previous Processing Problems:

Rotor arm for a mining tool

Material:

Alloy Steel 		The previous process was casting.
  • The cast part, because of its lack of directional grain flow, did not have the required strength for the demanding mining application.
  • Due to the lack of strength, part failures were occurring in the field, and the part had a short life span.
  • Costly part repairs and maintenance were necessary because of the frequent part failures.
Forging as the Solution:
Forging as the Soution
  • The part is now forged as a ring, with three torch cut sectors that are forged into journals.
  • Forging provides a continuous grain flow which ensures high part strength, integrity, and longevity.
  • The improved strength has minimized part failures, as well as the need for repair and maintenance.
Product/Application:
Previous Processing Problems:

Centrifuge bowl used in the corrosive environment of food processing

Material:

Ferralium® 255 Duplex Stainless Steel 		The part was previously centrifugally cast.
  • The customer required a stronger, more resilient centrifuge able to withstand heavy wear and tear, so production could be increased.
  • To manufacture a stronger centrifuge as a centrifugal casting, the RPM's would have to be increased, and the higher loading would have exceeded the attainable properties of the material.
  • The centrifugal casting die charge and process costs were high to start with, and a stronger centrifuge would have required a more costly material like titanium.
Forging as the Solution:
Forging as the Solution
  • Forging permitted the design change to a stronger centrifuge, while maintaining the customer's original alloy choice.
  • Forging a stronger centrifuge, able to handle increased service requirements, allowed the customer to increase production by 15%.
  • The forging cost for the improved centrifuge was actually 24% lower than the original centrifugal casting.
Product/Application:
Previous Processing Problems:

Hub for a steel mill rolling application

Material:

Alloy Steel
 Part was originally cast.
  • Casting failed to meet critical surface requirements, resulting in scrapped parts.
  • At times, inclusions were not found until after extensive finish machining, costing excess time and money for replacements.
Forging as the Solution:
Forging as the Solution
  • The hub is now produced by forging and torch cutting.
  • The part has higher strength and structural integrity due to forging's continuous grain flow.
  • The use of cleaner, forging quality material eliminated surface quality problems and rejections.
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