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Advantages of Converting Casting to Forgings

Possible Problems with Castings

From porosity to material inconsistencies, casting can cause more problems than solutions. But you can solve these problems by working with our employee-owners, we have advanced forging technology and the expertise of our employee-owners to produce forgings for applications that require more complex shapes. Consider converting castings to forgings for stronger, more sound and technically superior components and a better supply-chain solution.

casting vs. forging

Consider Forgings

Forging is a viable solution to your problem if you find yourself in any of these situations:

  • Your component serves as a critical part of a product’s design
  • The current design continually causes issues from your customer’s perspective
  • You waste valuable time and materials on questionable castings
  • You could be working on other projects versus re-machining parts (i.e. opportunity cost)
  • The long lead times for the casting design result in downtime and lost revenue
  • You spend considerable time searching for casting patterns or manufacturers

Why Forging?

Everyday economic and competitive threats, along with part failures, drive high-strength material users to seek metalworking alternatives.

Scot Forge evaluates conversions on a case-by-case basis.

We consider various factors, including the ability to redesign a product as well as the design requirements for the end-use application. Often, this requires engineers to challenge traditional methods and consider new technological advances.

Casting conversions can frequently lower total costs.

Forgings usually target a lower total cost when compared to a casting or fabrication. When we evaluate cost factors, such as product life-cycle costs from procurement, lead time and rework, as well as costs of scrap, downtime and further quality issues, the long-term benefits of forgings can far outweigh the short-term cost-savings of castings or fabrications.

Examples of recent conversion successes:

Construction equipment manufacturer

A customer’s product had a long history of issues due to poor casting quality. Working with Scot Forge, they were able to transition the casting to a forging which removed all re-work and weld repair from their process and allowed them to provide a better component to their customer. This saved an average of seven (7) processing hours per piece.

Defense contractor

Scot Forge collaborated with a customer to convert a 22 piece fabrication into a two (2) piece forging design, saving over 500 hours in welding costs per unit.

Mining equipment manufacturer

Our customer’s casting supplier was not able to meet their production demand, resulting in a potential loss of a significant amount business. Scot Forge was able to provide a solution that met the customer’s demand and delivery requirements at a lower total cost than the casting, saving money and defending business.

More examples are described in the cases below.

Product/application

Rotor arm

Material

Alloy Steel

Previous processing problems

The previous process was a casting.

  • The cast part, because of its lack of directional grain flow, did not have the required strength for the demanding application.
  • Due to the lack of strength, part failures were occurring in the field, and the part had a short life span.
  • Costly repairs and maintenance were necessary because of the frequent failures.

Forging as the solution

Today the part is forged as a one-piece forging.

  • Forging provides a continuous grain flow which ensures high strength, integrity, and longevity.
  • The improved strength has minimized part failures, as well as the need for repair and maintenance.
Rotator arm

Product/application

Centrifuge bowl

Material

Stainless Steel

Previous processing problems

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 RPMs would have to be increased, and the higher loading would have exceeded the attainable properties of the material.
  • The centrifugal casting tooling charge and process costs were expensive, and a stronger centrifuge required a more costly material.

Forging as the solution

Today the part is manufactured as a near net forging.

  • Forging permitted the design change to a stronger centrifuge, while maintaining the customer's original alloy choice.
  • The ability to handle increased service requirements due to a stronger centrifuge allowed the customer to increase production by 15%.
  • The forging cost for the improved centrifuge was 24% lower than the original centrifugal casting.
Centrifuge bowl

Product/application

Hub for a steel mill rolling application

Material

Alloy Steel

Previous processing problems

The part was originally a casting.

  • Casting failed to meet critical surface requirements, resulting in scrapped parts.
  • At times, inclusions were not found until after extensive finish machining.

Forging as the solution

Today the part is produced by forging.

  • 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.
Steel mill