There is a big difference between what a forging manufacturer can do to ensure success and what brokers do to put a good deal together – and the difference could cost you. Technology provides the means to procure components like never before. You have the information and freedom to buy what and when you want, from whom you want to. Although the choice can seem as simple as Nike or Adidas, Starbucks or Dunkin', and John Deere or Cat, at the core of these decisions is really just preference – they are priced about the same and have about the same quality.  However, you can't put a forged component in this same purchasing category. There are many things to consider when purchasing a forging. These considerations are critical to the cost and the ability of the component to meet your requirements. So, understanding what you are buying is key, which is why there is a big difference between what a forging manufacturer can do to ensure success and what brokers do to put a good deal together – and the difference could cost you. Functioning under the guise of a "contract manufacturer," brokers don't physically manufacture anything. Instead, their expertise lies in the business of drop shipping, logistics and outsourcing. Because brokers don't have expertise in manufacturing or producing forged parts, they don't have a need to staff engineering personnel to pre-engineered components. Instead, the primary function of a broker is to take your desired dimensions and shop them around to manufacturers, essentially looking for the lowest-priced provider. Because brokers work as middlemen looking for the cheapest way to produce a finished product, they are more like mediators between forge shops, machines shops, heat treatment facilities and customers. They'll arrange for only the purchase and delivery of components for you but might not give you vast options that could save you on overall price - or total cost of ownership. Essentially, you're committed to the decisions of a broker, which may not consider every aspect of your project or your business model.On the other hand, working with an experienced forging manufacturer could result in finding a better way to produce your component. This better way could be to choose a more suitable material for your application or manufacture your parts closer to the final shape , which would enable producing your part more economically to save on material and downstream operations like machining, heat treatment , and shipping.  Furthermore, when working with a forging manufacturer, the interest in your business is long-term. At Scot Forge, we value relationships and don't view your project as just the "one and done." Since our minimum order quantity is one, there is no project too small as long as your component falls within our minimum size requirements. Additionally, because Scot Forge has metallurgists in-house, along with the process and forge engineers, your component is more than just the lowest price option - it is cost-effective and reliable. By understanding what you value, we can determine how we can help meet your objectives, which allows us to find opportunities for adding more value. To support this thought, according to the Total Cost of Ownership Best Value Whitepaper, published by the University of Tennessee, even government agencies that traditionally relied on competitively bid "lowest price" policies have started to deploy Best Value concepts.  The example in the paper is of the rebuilding of the I-35 bridge in Minnesota. To balance cost, quality and timeliness as key factors in choosing the contractors that rebuilding the bridge. As a result, they selected a contractor with the highest price – yet had the overall Best Value resulting in one of the most successful bridge construction projects in history, winning dozens of awards and being erected in a staggeringly short timeframe of fewer than 18 months. So, when it comes to forgings, finding a partner who understands your project will be far more cost-effective in the long run than working with a company that will put together the lowest-priced option. This is not to say there aren’t brokers out there that do invest in customer relationships and seek to understand the needs of the end-user, but working with a manufacturer such as Scot Forge will help ensure you get your parts to spec on time.   Learn more by watching our Forging Buying 101 videos

Learn more about ultra-clean metals produced through a process called Vacuum Arc Remelting and the benefits they bring to forged bar. Bar Forgings are used in many applications, from ship shafts to gears in machines we use daily; and bar forgings found in high-value applications, such as applications that undergo extreme conditions, need metal grades of the highest quality. To reach these qualities, engineers can choose “exotic” metals, which inherently hold choice qualities. But, with these high-end materials come high-end prices. Another, more cost-effective, way to reach high-quality material properties is through remelting processes like Vacuum Arc Remelting or Electro-Slag Remelting. Both VAR and ESR help to produce clean material , reducing segregation and inclusions in steel or other alloys, refining them and improving grade properties – VAR is prevalent in the United States and ESR is more commonly seen in Europe, although U.S. ESR furnace capacity has been increasing over the past few years. The benefit of Vacuum Arc Remelting is cleaner materials with: reduced gas and oxide contents, improved homogeneity of the ingots obtained; improved ductility; greater uniformity of properties in the transverse, and longitudinal directions; improved fatigue properties; and uniformity of chemical composition. To produce these ultra-clean metals, VAR materials go through a secondary melting process conducted in a vacuum-sealed, highly controlled environment. The steels and alloys gain tight chemical tolerances through the removal of dissolved gases, such as hydrogen and nitrogen (if desired); the reduction of undesired trace elements; directional solidification of the ingot from bottom to top, which alleviates macro-segregation and reduces micro-segregation.  As mentioned above, VAR also provides oxide removal that is achieved through chemical and physical processes. The chemical process happens because less stable oxides or nitrides are thermally reduced by the carbon present in the alloy, allowing them to then be removed through the vacuum of the VAR process. However, in special alloys and high-alloyed steels, the non-metallic inclusions (e.g. alumina) are very stable, so they remain in the chemical makeup of the material. Other inclusions in the ingot will be removed physically by flotation that takes place during remelting (impurities float to the top where they get cut off). Any remaining inclusions are broken up and evenly distributed in the cross-section of the solidified ingot. VAR grade materials are found in aerospace applications, including the “superalloys” needed for extreme applications of temperature and pressure. VAR steels are used in rocket-booster rings, landing gear and high-pressure tubes. Oil and gas , as well as the nuclear industry , are utilizing the remelt of reactive metals and their alloys. Typical VAR grades: 4340 VAR9310 VARPH Stainless300M3NiCrMoV300 & 400 Series Stainless To learn more about VAR grade properties and availability, contact a member of the Scot Forge bar team today!

A popular thought is that the mining and drilling industries are to blame for the state of the world; however, there are benefits to mining that cannot be overlooked. As people focus on preserving the planet's natural resources and are leaning more heavily on renewable energies, the popular thought is that the mining and drilling industries are to blame for the negative state of the world. However, while we do need to be aware of our carbon footprint, there are benefits to mining that cannot be overlooked.  (Discover the full infographic at https://mineralsmakelife.org/resources/our-energy-future-depends-on-mining/ ) The mining industry supports our everyday life. The mining industry not only provides the elements for the innovations of tomorrow, but the U.S. minerals industry also supports more than 1.1 million jobs. In addition, estimations indicate that another 3.5 additional jobs are created elsewhere in the economy for every metal mining job compared to every non-metal mining job producing around 2.6 other jobs. With mineral mining directly employing more than 400,000 Americans today, and more than 700,000 indirectly employed, the mining industry is a significant driving force in our economy.  Aside from supporting thousands of jobs, the mining industry provides raw materials, minerals and metals critical to our economy. They provide the foundations for modern living, innovation and engineering achievements. Take platinum, for example; it is used in more than 20 percent of all manufactured goods. Platinum is essential to creating everything from personal computers, flat-screen TVs and hybrid cars to life-saving medical devices. Today, the National Mining Association (NMA) reports that U.S. manufacturers rely on 29 of the 35 "critical" minerals, as the Department of Interior designated, essential to a strong U.S. economy.   Mining to Protect Health, Save Lives Life-saving medical devices would not exist without many of the metals and minerals that are mined. There are even medicines that doctors and patients rely on every day that would not be available. For example, minerals are crucial materials to operate CAT scan devices. Copper, silver and gold are mined here in the United States to support these machines. Lithium is found in pacemakers, defibrillator machines and other portable electronic equipment, while titanium is used in surgical pins, bone plates, wires, rods, stent-electrodes and screws. These are a few ways Americans and the world rely on metal and minerals for their health. Mining for Advanced Energy Technologies Renewable energy technologies rely on minerals. Copper is just one of these minerals. It is used in the wiring of solar panels and plays a significant role in components for wind turbines. Not only is this mineral a key player in energy production, but it also is critical to renewable energy storage as copper is used in lithium-ion batteries. On the topic of energy storage, another mineral frequently used is manganese. It is an additive in steel alloys and is found in electric vehicles and wind-and-solar power-storing batteries, along with lithium. Only procured through mining, these metals and minerals are also in both off-shore and on-shore wind power projects . Mining to Keep Americans Safe Metal and minerals are vital components of our national security; the United States Department of Defense utilizes more than 750,000 tons of metals and minerals annually, which have U.S. sourcing requirements. For example, armor plates are comprised of chromium, nickel and molybdenum combined in precise amounts and applied to purified scrap metal to protect people by withstanding explosions and gunshots. At the same time, airborne equipment employs beryllium to detect and destroy improvised explosive devices (IEDs). Mining , directly and indirectly, impacts all of us every day, from the phone that connects you to the world to the innovations in renewable energy that power homes and vehicles. Scot Forge helps support mining by developing and manufacturing forged components that are more sustainable as they require less material and are reliable, creating less scrapped parts and waste.

The robust and evolving nature of the forging industry in the United States and the nation's ability to meet the growing demand for forgings in various sectors, including defense, energy and aerospace. In recent years, there has been a prevalent misconception regarding the limited forging capacity in the United States. Due to perceived limitations in forging capabilities, some have expressed concerns about the nation's ability to meet the growing demands of various industries, including defense, energy and aerospace. However, it's crucial to address and dispel these misconceptions to showcase the robust and evolving nature of the forging industry in the United States. U.S. Forge Capacity: Unraveling the Misconception Growing Industry Presence: Contrary to the belief of limited forging capacity, the United States boasts a significant and growing presence in the forging industry. Forging facilities, like Scot Forge, have invested in state-of-the-art technology and advanced manufacturing processes to enhance their production capabilities. These facilities play a pivotal role in meeting the diverse needs of industries ranging from automotive and defense to infrastructure and clean energy. Advanced Technologies and Innovation: There is a false impression that often arises from a lack of awareness about the advancements in forging technologies. Modern forging facilities in the U.S. employ advanced techniques such as precision forging, closed-die and semi-closed-die forging and additive manufacturing. These innovations increase the overall capacity and allow for the production of complex and near-net-shaped components, debunking the notion of limited capabilities. Strategic Partnerships: The forging industry in the U.S. has forged strategic partnerships with research institutions and government agencies to foster innovation and address potential downstream capacity constraints. Collaborative efforts between industry players and academia have led to the development of cutting-edge processes, materials and quality control measures, ensuring a robust and competitive forging sector. Diverse Applications: While defense and aerospace are key consumers of forged components, the industry serves a myriad of sectors, including mining, semiconductor manufacturing and construction. This diversity in applications showcases the adaptability and versatility of U.S. forging facilities, proving that capacity is not limited but rather multifaceted. Forge Capacity: Addressing Industry Challenges Workforce Development: We actively participate in workforce development and apprenticeship programs to strengthen the forging industry further. By reaching out to educate young people on their options for career paths, we have established a thriving pipeline of new talent. Furthermore, by offering training programs and initiatives that attract skilled professionals to the field we contribute to sustaining and enhancing forging capacity in the U.S. Infrastructure Investment: Upgrading and expanding infrastructure within forging facilities will be crucial for meeting the evolving demands of various industries. We reinvest our own money, to the tune of $500 million over the last 15 years, in facilities and assets that will continue to support the needs of the nation for years to come. Our continued investment in cutting-edge equipment and technology will ensure that the forging sector remains at the forefront of manufacturing capabilities. In conclusion, the misconception of limited forging capacity in the United States is far from the truth. The forging industry in the U.S. is robust, technologically advanced and continuously evolving to meet the diverse and growing needs of various sectors. By dispelling these misconceptions, we can appreciate the strength and adaptability of the forging sector, positioning it as a key player in the nation's industrial landscape. As the industry continues to innovate, forge ahead and debunk myths, the future of forging in the U.S. remains promising and dynamic.

Scot Forge reviews the numerous applications in forgings and the different methods for testing. Forging is one of the oldest skills known to man and it’s tough to envision manufacturing and even life without the parts created by forging. Some of the applications for forgings can be straightforward, such as rings for gears and flanges or bars for ship shafts. In contrast, others are very complex, such as hollows for oil country tubular goods (OCTG) and pressure tubing for power boilers or domes for nuclear waste storage. There are numerous applications for forgings. As a result, there are many manufacturing and testing standards that forgings must meet. Forgings are commonly created to the standards of the following organizations: •  AISI - American Iron and Steel Institute • ANSI - American National Standards Institute • AMS - Aerospace Material Standards • API - American Petroleum Institute • ASTM - American Society for Testing and Materials • ASME - American Society of Mechanical Engineers • NAVSEA - Naval Sea Systems Command • DIN EN - European National Standards And, just like the applications of the forgings, the methods for testing can be varied. For instance, testing from a ring to a tube for a critical, high-pressure use is not as simple as it first appears. Numerous standards could apply; it depends on the application. ASTM A668, for example, references six different standards. A275/A275M Practice for Magnetic Particle Examination of Steel Forgings A370 Test Methods and Definitions for Mechanical Testing of Steel Products A388/A388M Practice for Ultrasonic Examination of Steel Forgings A788/A788M Specification for Steel Forgings, General Requirements E290 Test Methods for Bend Testing of Material for Ductility E340 Practice for Macroetching Metals and Alloys Each standard specifies procedures for measurements or test methods. As far as material standards, the mill typically calls out the capabilities of material based on sound forging practices. There are many tests available to meet criteria standards and ensure part quality that helps find indications, or imperfections, in the material – magnetic particle test (MT), dye penetrant test (PT) and ultrasonic inspection (UT). MT and PT discover surface flaws; they are relatively easy and inexpensive. MT uses a magnetic field with a solution containing iron filing particles that highlight an indication in the forging as the iron particles collect at the magnetic flux that leaks from a crack or void. PT can be more time consuming as it requires applying a liquid penetrant to the forging and then removing it; a developer must then sit on the piece to draw out remaining penetrant from any cracks or crevices. UT is a volumetric test and uses sound waves to find gaps in the forging; when the sound wave hits a void, it ends back a spike in the ultrasonic display, which is called an indication. All these methods require a finished surface to allow for accurate readings. Performing a test is one process, but evaluating a forging to determine if it is acceptable is a different process altogether. For instance, it’s not uncommon to require a UT inspection by requesting “UT per ASTM A388.” The problem, spelled out in this document, is that “this practice is intended for application to forgings, with a wide variety of sizes, shapes, compositions, melting processes, and applications. It is, therefore, impracticable to specify an ultrasonic quality level which would be universally applicable to such a diversity of products.” The standard does not list exact acceptance requirements other than indications that cannot exceed an acceptable size. Since metal transitions from a liquid to a solid, there are always some particles that get trapped, much like air bubbles or dirt would in ice. While most particles get eliminated during the forging process, some could remain at an acceptable level. So, this is why it is essential to discuss acceptance criteria, list the voids or flaws that might be found as well as the limits or extent that they are permitted. A good example is specifying the amount of non-metallic inclusions that may be permitted. The specification would include the sizes and spacing between non-metallic inclusions that must be measured and evaluated, which helps set expectations for both the customer and the manufacturer. It is important to note that there are ways to reduce the risk of indications in a forging, such as using refined material like Vacuum Arc Remelt (VAR), but increased purity results in increased cost.  Finding the balance between acceptable quality and cost-effectiveness is often tricky. Not to mention how the acceptance criteria vary by each forged product. So, it is essential to carefully review documents that support the requirements of the end-use application. From the simple to the complex, a partner like the Scot Forge employee-owners can help guide you through this process.

Take a peek into what makes Scot Forge different, how we forge our future by succeeding or failing as a team and the tradition of the SPIKE Award. Tradition. Loyalty. Pride. When you have a company with more than 125 years of history, tradition, loyalty and pride become infused in not only the culture, but the employees themselves. At Scot Forge, you can sense the essence of tradition, the vigor of loyalty and the notion of pride the moment you arrive at any of our three facilities. This has much to do with the fact that we are an employee-owned (ESOP) company and have been for more than 40 years.    Employee-ownership means that we forge our future by succeeding or failing as a team, which is significantly impacted by the principles above. We must take pride every day in what we do and how we do it to succeed in creating the best possible outcomes for our customers that extend beyond simply forgings. After all, what we develop impacts lives through strengthening infrastructure , improving aerospace designs, powering the world through mined commodities and bolstering our national defense .   Furthermore, for success, we must have loyalty internally to hold ourselves and each other to high standards. To achieve these standards, we leverage each other’s strengths, exhibit servant leadership in all that we do and attack the problem, not the person, which would not be possible without trust. Our loyalty to our customers is another facet of success. What we do would not be possible if we weren’t devoted to delivering high-quality, essential forged solutions on time, as promised.   Finally, establishing pride and developing loyalty couldn’t take place without tradition. At Scot Forge, “plaid is pride” it is our tradition to wear plaid to honor the Scottish roots of Pete “Spike” Georgeson, our ESOP founder.  Plaid also represents the way we rely on each other through success and failure, and the way that we unite with our customers. Another tradition is the recognition and reward of employee-owners who demonstrate the values of commitment and contribution with the SPIKE Award.   The SPIKE Award was founded in 1987 and named in honor of Pete. It celebrates employee-owners who have gone above and beyond the call of duty for the past year. Once a year, around August, employee-owners vote for fellow employee-owners who make an impact daily and truly embody the Scot Forge values of safety, personal accountability, integrity, continuous improvement, learning and collaboration.   By living these values daily, our employee-owners have created an environment that has surpassed just a job or a place to work and formed a family. Some employee-owners have been with Scot Forge right out of high school and are retiring after a 25-year career. While others have worked in different industries who now call Scot Forge home.  But, we all work toward one common goal, to leave our company better than we found it. Congratulations and thank you to this year’s SPIKE Award winners!   To learn more about Scot Forge and the opportunities we have in machining, forge, heat treat, operations, engineering or office positions call us or take a look at our careers page.

In July, Scot Forge made a big announcement...Ron Hahn has taken over the role of President and COO. In July, it was announced to the employee-owners of Scot Forge that Ron Hahn was promoted to President of the company but would continue to maintain his role of Chief Operating Officer. This is a natural progression for Scot Forge; Ron has a long history with the company and has been sharing many of the President’s responsibilities with CEO and Chairman of the Board, John Cain, since becoming COO in 2011. Ron joined the company in 1990 as an intern in Maintenance and Engineering performing all sorts of hands-on tasks with the equipment care and maintenance. That year, he was the recipient of the Peter I. Georgeson Scholarship from the Milwaukee School of Engineering (MSOE). His potential was quickly realized and in 1991 he was hired on full-time. He continued to work in Engineering and in 2001 was promoted to the Engineering Manager. In 2006, Ron earned the opportunity to serve as the Project Crew supervisor. By 2008, Ron was promoted to Director of Manufacturing which was followed by the promotion Vice President and COO in 2011. Ron has contributed to the success of Scot Forge in many ways over the course of his career, but his favorite project has been the design and engineering of the 5,500 Ton press in Spring Grove. Ron was responsible for putting the business case together for the asset but recalled with pride how it took the dedication of the entire Engineering and Maintenance teams to get the press up and running within a strict deadline of a year to meet some critical customer needs. He stated about the project, “The fun part was seeing the team come together. There was a mission and the team came together to make that happen.” When asked about his newest promotion, Ron stated that he’s most looking forward to building on the relationships that make us all stronger…with employee-owners, customers, partners, suppliers and competitors. Since he has worked on both the operations and commercial sides of the business, he understands the advantages of these long-term partnerships and how they translate to benefits for all parties involved. Since the transition of President from John to Ron happened during healthy economic times, Ron can focus on his strategy to continue to build on the strengths of our culture, order fulfillment and on-going customer learning. “I’ve been here 27 and a half years,” he stated, “and the culture is what differentiates us. We’ll continue to grow and invest where our customers need us. [Regarding] our business development ... we're not stopping that either. Diversification in our markets is an important part of our strategy, especially with our employee-ownership culture. Our strategy will always be looking to grow where our customers need us.” Ron describes his priorities as faith, family and work family. He has two children who both attend UW-Madison. He loves to spend his free time golfing with his kids and his wife, Cami. John Cain will continue to serve in his role as the CEO and Chairman of the Board at Scot Forge. Read John’s full letter to the Scot Forge employee-owners about this long-term transition. Read the Full Letter

Joining the ranks of other prominent companies such as Honeywell International, Caterpillar Inc., Lockheed Martin, ExxonMobile and Alcoa, Scot Forge becomes the first ever forging company in the United States to receive this honor. EHS Today names Scot Forge as one of America’s Safest Companies in 2014 Since 2002, EHS Today ( Environment, Health, & Safety Today ) has recognized America’s Safest Companies, honoring those whose focus is on developing and maintaining world-class safety cultures. Each year, companies from all types of industries submit applications for review and EHS selects 10-15 standouts to receive this prestigious award. This year, we are proud to announce that Scot Forge Company has claimed one of the 2014 spots. Joining the ranks of other prominent companies such as Honeywell International, Caterpillar Inc., Lockheed Martin, ExxonMobile and Alcoa... Scot Forge becomes the first ever forging company in the United States to receive this honor.   To be considered for the title of America's Safest Company, Scot Forge had to demonstrate “support from management and employee involvement, innovative solutions to safety challenges, injury and illness rates lower than the average for the manufacturing industry, comprehensive training programs, evidence that prevention of incidents is the cornerstone of the safety process, good communication about the value of safety, and a way to substantiate the benefits of the safety process”. (America’s Safest Companies, EHS Today) While this award means a lot to the company, it’s just the beginning. Even though Scot Forge is doing very well by external measures, internally the employee-owners know they can do significantly better. The company’s culture of continuous improvement and commitment to safety means their ultimate goal is zero injuries… and they won’t be satisfied until that goal is sustained. At Scot Forge, everyone is working towards a common goal - to go home at the end of each day without accidents or injuries. By fostering a low-risk work environment, employees stay productive and can focus on other things, like producing quality, precision forged parts. And by taking care of themselves, the employee-owners know they can continue to take better care of their customers. Scot Forge… We’ve Got You Covered! Read the whole SafeStart Success story! Download Now

Forty years ago, the sinking of the Edmund Fitzgerald became the deadliest shipwreck — and greatest mystery — on the Great Lakes. Scot Forge explores the tragedy and the lessons learned about how metals and their applications interact with the harsh, sometimes violent conditions of the open waters. The SS Edmund Fitzgerald underway. Photo by Winston Brown. Forty years ago, the SS Edmund Fitzgerald , the “Pride of the American Flag,” left Superior, Wisconsin at 2:15 p.m. en route to a steel mill on Zug Island near Detroit, Michigan. With a cargo of 26,116 long tons of taconite ore pellets, the ship was the largest vessel of its kind to sail the Great Lakes. Its captain was a 40-year veteran. Twelve hours later, during a severe winter storm with winds of 52 knots and rogue waves up to 35 feet high, the “Mighty Fitz” sank at approximately 7:10 p.m. No distress signal was ever received. All 29 of her crew were lost. Forty years later, the sinking of the Edmund Fitzgerald remains the deadliest shipwreck — and greatest mystery — on the Great Lakes. Speculations and Lessons Learned Tragedies like the sinking of the Fitzgerald teach us a great deal about how metals and their applications interact with the harsh, sometimes violent conditions of the open sea. During WW2, U.S. shipbuilders struggled to understand why the hulls of their mighty Liberty vessels were literally cracking — some splitting in half. The answers were found in both metallurgy and manufacturing. Metallurgists learned that the hull materials in use at the time could not withstand the stresses encountered at sea in very cold climates. Though these waters had been in active use for decades, the change from riveting to welding revealed a fundamental weakness in the hull materials—a transition from tough to brittle at low temperatures. This flaw had previously been countered by the riveted assembly method. When small cracks formed, they were arrested by the rivet holes and did not propagate to any significant degree. When welding replaced riveting, however, no features were available to prevent the crack from spreading. There were nearly 1,500 occurrences, 12 of which resulted in ships breaking completely in half. The realization that metal properties can be temperature-dependent resulted in both new test methods and new alloys to reduce the risk mariners face in cold climate shipping. For the SS Edmund Fitzgerald , the exact cause of the wreck is still undetermined to this day. However, based on clues resting at the bottom of Lake Superior, theories are abundant. One theory speculates that a couple of the Fitzgerald 's giant metal cargo hatches near the center of the vessel had weakened and caved inward from the force of the violent waves, allowing massive amounts of water to swamp the cargo hold, overwhelming its pumps and sinking the ship in a matter of minutes. Although it is was never substantiated, this hatch theory — like the Liberty failures — forced shipbuilders to ask, “How do we make vessels stronger?” One of the potential means of improving a ship’s strength is to incorporate more forged components. Forging, by nature, is stronger and more durable than casting or welding. Thanks to a variety of engineered materials, expanded facilities and new technologies, marine designers now have more options for forged parts than ever before. We asked Pat Nowak, Process Metallurgist for Scot Forge, what the best applications of forging are in marine environments: “For making new ships or repairing existing ones, manufacturers can forge everything from ABS shafts/bars to hollow tubing, piston rings, gears, support bearings and a wide array of custom components.” Same Waters. Better Metals. “Today we work with stronger and lighter metals that have dramatically changed how we approach maritime applications,” Nowak explains. “We have access to new cutting-edge alloys like duplex and super duplex stainless steels, bronze, nickel and aluminum alloys that can better handle corrosive and extreme environments. In fact, many of these forging materials are so strong and corrosion-resistant that we do not even need to paint them to protect them from the elements.” New Super Duplex Alloys A super duplex alloy is the most corrosion-resistant, as measured by Pitting Resistance Equivalent Number (PREN). Super duplex materials have a PREN greater than 40. Bronze Alloys Bronze alloys are extremely popular today for their looks, strength and resistance to corrosion. While they have always been used to make bells, mirrors, weapons and sculptures, they are more prevalent today because the way they are engineered and processed, making them a more attractive option for design engineers. High Yield Strength Materials Today, we also have access to high yield strength (HY) materials that are easier to weld yet ideal for applications that require toughness. They are often used on naval vessels and in other military applications. These alloys come in three grades: HY-80, HY-100 and HY-130, and are designed for low temperatures. Stronger Metals. Smarter Tools. Not only has the quality of engineered metals evolved over the past 40 years, but so have the tools to forge them. Today, world-class manufactures like Scot Forge use 3D computer modeling and forging simulation software to expanded the possibilities what parts can be forged. As a result, today’s marine engineers are able to design vessels that are bigger, lighter, faster, more fuel-efficient and — most important of all — safer for the crews who sail them. Forging a quicker solution to expedite ship repairs and avoid costly dry dock time

Scot Forge discusses hot rolled bar vs cold rolled bar, and forged bar processes to find the right solution for any application. Call today! In the world of bar products, there are different ways to manufacture bars and some different things to consider when purchasing bar. Often lead time, quantity, and quality are what drive decisions when purchasing bar . The end-use application can also play a significant role and can range from a product that utilizes the full length of a 20-foot bar to portions of the bar cut and machined to a unique geometry. In this blog, we discuss the options that can provide both high and low quantity options for buyers - Hot Rolled Bar, Cold Rolled Bar, and Forged Bar. (Please note - There is another process which pushes molten bar through a die called hot-drawing or extruding. This method is not ideal for low quantity purchases.) So, Hot Rolled vs Cold Rolled and Forged Bar Rolling and forging bar boils down to the same fundamental process of reducing the thickness or changing the cross-sectional area of metal by compressive forces. In other words, a large piece of metal known as a billet is pressed down to the size, shape, and length required for a project. This process not only gives the bar shape, but it also adds properties of strength to the bar.  What is Hot Rolled Bar? This is the process of heating a billet to more than 1000 degrees Fahrenheit, above the recrystallizing phase of metal so that it’s workable, then rolling it through a planishing mill or rollers to give it its shape. Heating the metal is vital because changing the molecular structure of the metal form dendrites (thread-like sporadic structures) to grains (organized block-like structures), which only happens when metal is in a malleable state. The creation of stronger metal is not only due to the formation of the grains, but the directional grain flow achieved when the bar is rolled. Pros & Cons Hot Rolled Bar Hot rolled bar is quick and creates single or multiple pieces easily. Unfortunately, where hot rolled bar falls short is with dimensional tolerances. When the metal cools, it contracts and that leads to the likelihood of warping, areas of varied thickness, and a scaled finish, which means machining is required if dimensional precision or finish type is essential. Lastly, with hot rolled bar, timing is everything. If the rolling cycle is missed lead time is drawn out since additional bar wouldn’t be produced until the next mill progression. What is Cold Rolled Bar? This process takes everything we just discussed about Hot Rolled Bar and adds a step. When the bar reaches near-room temperature, it is drawn through dies or rerolled in a progressive rolling process. This additional step inherently adds strain hardening to the bar because it is worked after recrystallization. Strain hardening can only harden the metal so much, the bulk of hardening is achieved during the molecular restructuring provided by hot rolling, depending on the grade.   Pros & Cons Cold Rolled Bar Cold rolled bar has better dimensions, straightness, and increased yield strength. It, again, is used for single or multiple piece requirements. But, with the extra step or rerolling, cold rolled bar is time-consuming and can extend lead times. Unlike a hot rolled bar, however, additional machining for precision isn't required, and the finish is not as scaled. What is Forged Bar? This process, like a hot rolled bar, takes a billet and heats it until it is malleable. This is where the processes differ, rather than rolling the bar to get it to size, forging either hammers or presses the bar to the rough dimensions required. The operation gives the bar a 3:1 reduction ratio minimum, which means that the grain sizes are much smaller and tighter in a forged bar, and it consolidates the centers if there are any piping issues. Then, depending on the diameter of the bar, the bar is put through a planishing mill giving it a smooth, rounded surface.   Pros & Cons Forged Bar Forged bar process takes the best of hot rolled and cold rolled bar and achieves it quickly and efficiently. These bars maintain dimensions and straightness as they cool while having an even higher yield strength because of forgings' unique capability of producing sound-centers during the forging step. The 3:1 minimum reduction helps eliminate any centerline non-consolidation issues that affect bar quality. Unlike the additional step in cold rolling, the extra step of rolling after forging is done while the bar is hot, so there is no time wasted on additional processes after cooling. Forged bar can be used for single or multiple piece requirements and produced on demand. The other significant advantage is for large diameters. The rolled bar is produced to a specific maximum size where the forged bar has a broader span of diameter capabilities.    If you are new to forging or want to compare bar quality, the Scot Forge Bar Team is here to help you navigate your options. Contact our Scot Forge Bar Team for more information about forged bar. Forging may not always be the best option for your project, and if that is the case, we are happy to point you in the direction of vendors we know and trust.

The 700+ employee-owners of Scot Forge have orchestrated a very special message for you and your loved ones to help celebrate the season! Click Play Below to Enjoy the Show! May your holiday season be wrapped up with cheer and filled with prosperity to forge the New Year! Scroll down to see the full Scot Forge Cast and Crew Thanks for watching! To learn more about the services and capabilities the employee-owners of Scot Forge provide, check out our Virtual Plant Tour or view our Culture Video . Enjoy the Holidays!

Following today’s best practices, we focus less on the lowest price and more on our customers’ total cost of ownership (TCO). Whether that means reducing manufacturing costs, improving part performance or minimizing material waste, our team brings the knowledge of custom forging experts to work in your plan and help you achieve long-term cost reductions and improved lead times. Evaluating Price vs. Total Cost How Scot Forge Adds Value Where Our Customers Need It Most As a leading forging supplier to many industries, Scot Forge understands that our strong industry relationships derive from our ability to deliver measurable value to our customers’ bottom line. Following today’s best practices, we focus less on the lowest price and more on our customers’ total cost of ownership (TCO). Whether that means reducing manufacturing costs, improving part performance or minimizing material waste, our team brings the knowledge of custom forging experts to work in your plan and help you achieve long-term cost reductions and improved lead times. TCO: Best Practices to Help Buyers Determine Real Costs vs. Price In the past, the gross profit margin was a measure used to determine profitability. The basic equation of subtracting the cost of goods sold from net sales assumes that the easiest way to reduce the costs of goods sold would be to reduce the purchase price of materials and components. However, price is only one part of the picture. To evaluate value solely based on price can lead to higher costs overall. Think of this: do you value a supplier who also offers valuable knowledge and resources to help you solve problems? Many companies now realize that effective partnerships motivate suppliers to spend their limited resources with their partners vs. those who only focus on price. Instead, companies can partner with a few suppliers who hold the expertise to look at the big picture. Manufacturers who have insight into how their products impact their customers’ operations, and a longer view of the supply chain, can make specific recommendations for improvements. The value can significantly contribute to the bottom line. Scot Forge adopts TCO practices with its customers to help them improve efficiencies, costs and lead times. Optimizing Your Specifications and Manufacturing Practices Our technically trained account managers, Forge Development team and metallurgists can increase your product value with customized solutions that meet your existing requirements. Even the simplest material change or process modification has helped many Scot Forge customers realize significant savings. Below are some measurable examples of how Scot Forge reduced the total cost of ownership (TCO):  Improved Lead Time  Past practices on a customer part called for normalizing, quenching and double tempering; however, these practices ran up costs and production times. After discussing the end-use application and requirements, our team realized these were unnecessary steps that would affect the part performance. In fact, these steps were only added to solve a consistency problem their previous supplier was facing. By eliminating the normalizing and second tempering operations, enhanced the profitability of their component, and reduced lead time by weeks.  Previous requirements on another customer component called for meeting both a minimum tempering temperature and a hardness range on certain parts; this process often resulted in a re-quenching operation, which resulted in lengthened lead times. Through temperature modification, Scot Forge met the specification the first time and shortened the lead time by four weeks.  Lower Part Costs  A customer was looking for cost reduction assistance with a gear application to meet the hardness requirements of the 4340 material initially specified. Our team recommended substituting another 4100 series material for 4340, which lowered part costs by 10% while still meeting minimum Brinell requirements. Another customer was previously specifying Vacuum Arc Remelting (VAR) material for a pinion shaft in another scenario. Lead times were unacceptably long, and the material costs were high. Scot Forge realized that by switching from VAR material to another cleanliness technique, the customer would reduce their lead time by months and reduce material costs by more than 45% - without sacrificing product quality.  Reduce Marking Costs For part identification purposes, a customer previously specified elaborate markings on each part, then routinely machined them off upon receipt. Scot Forge introduced a more efficient process that uses a simple purchase order and heat number to identify each part, saving time and excess marking costs. Innovative Engineering Brings Solutions Over Products Our Forge Engineering team brings more than 90 years of combined experience to your project, including first-hand blacksmithing and modern simulation technology. They have developed a unique semi-closed die forging technique that allows for the flexibility of open die forging with the near-net shape capability of closed die. This method enables converting pieces with unique geometries, from castings or fabrications to forgings that were once thought impossible or cost-prohibitive.  Computer Modeling & Simulation Reduces Costs and Turnaround Times Our Forge Engineering team possesses a full range of simulation capabilities that enable more precise tool design and optimal forge process plans before producing an actual forging. As a result, material and machining requirements are reduced, minimizing costs and turnaround times. Our accurate simulations model a wide range of metalworking and material characteristics, including:  Complex shapes  Upsetting Forward extrusion Back extrusion Gear forming Stress analysis Heat treat modeling Grain flow characteristics Custom Alloy Development Can Save Material Costs, Scot Forge in-house engineers and metallurgical experts can join your team to study and evaluate alloy compositions. We can help you create materials capable of meeting the strict criteria for forged components used in markets such as maritime , gearing , power generation , aerospace and defense applications. The result is the development of alloys that offer better properties with potential material cost savings.  A real-world example: As an extension of our customer’s team, Scot Forge industry experts discovered a recurring roadblock during joint discussions around their forged aluminum products - the customer needed aluminum with excellent fatigue endurance, toughness and corrosion resistance characteristics. Our in-house team worked with outside experts to evaluate suitable aluminum alloy compositions capable of meeting the strict criteria for forged components used in naval, aerospace and defense. From this collaboration, we discovered a variation of aluminum 6013 that, with a thermal treatment, adapts well for many forging applications. Scot Forge devised a proprietary processing method for aluminum 6013 and dubbed it Highlander 613™. Originally, Scot Forge developed Highlander 613™ as a better alternative to the traditionally forged alloy 6061. However, after reviewing and optimizing the material’s forging properties, we have also found it to have substantial benefits compared to aluminum alloys of the 7XXX and 2XXX series as an all-around versatile product. Partner with Us If you're ready for a partner to develop solutions for your project, Scot Forge and its team of engineers can deliver. Our knowledge and expertise will help you reduce costs, improve lead times and offer innovative ideas to lower your total cost.