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Forging can often create economic advantages over other metalworking methods that save time and materials, as well as improve production efficiencies. Scot Forge employee-owners collaborate with you to discover the most viable solutions for your project. Our highly trained account managers, forge engineers, process engineers and metallurgists add decades of knowledge and experience to your team.
Forging can measurably reduce material costs since it requires less starting stock to produce many part shapes and can achieve near-net shapes, saving on scrap costs.
By minimizing the number of components in a fabricated part and enhancing design, Scot Forge can produce parts with increased quality while reducing overall cost and production time.
Forging also can yield advantages in machining, lead time and tool life. Savings come from forging to a closer-to-finish, or near-net, size than what is capable by alternative metal sources such as torch cutting plate or boring bar. Therefore, less machining is needed to finish the part, with the added benefits of shorter lead times and reduced wear and tear on your equipment.
Often discovering a defect in a cast part doesn’t happen until a part has been on a machine for hours, which can be a headache. But, when this happens to multiple parts it can be a nightmare. It takes time and money to replace parts, puts hours on the machine and increases labor costs, not to mention the lost opportunity cost.
Because forging has a 3:1 minimum reduction, porosity and veining are eliminated yielding improved structural integrity. Coupled with weld-free design, forging can dramatically reduce part rejection.
Scot Forge has many different sizes of starting ingots and billets on hand, providing a wide variety of ready-to-forge inventoried grades. Using the forging process, the same part can be produced from many different sizes of starting ingots or billets, allowing for a wider variety of inventoried grades. This flexibility means that forged parts of virtually any grade can be manufactured more quickly and economically.
For example, torch cutting a ring from plate (A), all corner stock and the full center slug are lost, as a result you pay for the excess material. With a forging (B), the part is shaped to a near-net size with minimal waste and optimized use of starting stock.
When hub shapes are achieved through machining solid bar stock or flame cutting plate, waste is an inescapable part of the process.
Custom forging of hub shapes improves quality, lowers material costs, and offers maximum flexibility.
Castings are not always economical and can extend deliveries. Machining from a large block or plate can result in excessive machine times.
Our forging and torch cutting capabilities allow for intricate jobs to be manufactured economically and with shortened lead times.
Centrifugal castings are not always economical and can extend deliveries.
Custom hollow forgings offer consistently high quality, often at lower costs and with quicker turnaround times.
Continuous grain flow shown on a stepped O.D. and I.D. in the as-forged condition.
The same part shown with columnar grain flow in the as-cast condition.
Note extra stock on the O.D. and I.D. required for centrifugal casting vs. forging
Flame cutting a ring from plate is not always viable when meeting material requirements, or economical.
A custom-forged ring allows greater versatility and improved quality while reducing material cost.
Machining a solid bar to form a step-down causes wasteful use of material, labor and time.
Custom-forging the bar to form a step-down lowers the cost for a value-added part.
Rolled and welded or cut rings from plate are susceptible to fatigue, and carry excess material and processing costs. In the cases below, these common problems were solved by switching to the forging process.
Three different metalworking processes were attempted to make one ring: a forging, a casting, and a rolled and welded plate.
Today a forged, profiled seamless rolled ring produces unsurpassed structural integrity.
The part was previously produced as a cast ring, with high maintenance and repair costs.
Today the part is made as a contoured forged ring.
The past production process involved torch cutting a heavy wall ring from plate.
Today a custom-forged rolled ring allows greater size versatility while oftentimes reducing waste and material costs.
Part originally consisted of three components: one rolled and welded plate and two forged rings welded to the ends.
Today the part is made as a single forged piece with integral flanges.
Previously the part was made from a cast head welded to a hot rolled bar.
Today the part is made as a one-piece forging.
The former part was a rolled bar welded to a forged blank.
Below are some examples of how forged hollow products have served as a customized solution for many of Scot Forge's customers—providing a stronger, high-quality product while eliminating excess time, cost and material waste. As you can see less machining is needed to finish the part, with the added benefits of shorter lead times and reduced wear and tear on your equipment.
Formerly, a solid steel bar was bored, machined, heat treated, and then finish machined with a tapered inside diameter.
Off-the-shelf tubing was previously used to form this part.
A centrifugal casting with a straight I.D. and single-step O.D. was formerly used.
Today, a hollow-stepped forging is produced with an integral-stepped I.D., delivering higher value with a stronger, near-net shape.