One of the forging industry’s biggest challenges is finding ways to increase die life, a parameter that is fundamental to efficiency and profitability. One way to achieve this is through the process called flood welding, a high-speed, high-deposition weld-metal recovery of a worn forging-die cavity.
Using the metaphor of old, less-efficient cars compared with modern vehicles, the authors suggest that using age-old tool-steel grades may not measure up to the performance needed from modern forging die steels in certain applications.
Ellwood Group Inc. of Ellwood City, Pa., will acquire McInnes Rolled Rings, a manufacturer of seamless carbon, alloy and stainless steel rolled rings. The deal is scheduled to close on March 31, and Ellwood expects to run Erie, Pa.-based McInnes independently as a wholly owned subsidiary. Operations at both companies are expected to continue seamlessly throughout the acquisition process. The deal fits Ellwood’s strategy to provide quality metals and custom-engineered components for critical applications around the world.
Direct metal deposition (DMD) is a powder jet additive-manufacturing (AM) technique that can be used for low-cost build, repair, hardfacing and reconfiguration of forging dies. The technique has also been used to add features such as flanges and bosses to forged parts to improve their functionality. This article uses four case studies to examine this technique in detail and compares its merits and limitations to conventional and other AM/welding techniques.
A group of forging professionals recently gathered in Long Beach, Calif., to attend the Forging Industry Educational and Research Foundation’s (FIERF) 32nd Technical Conference. Attendees were treated to a great plant tour, two days of technology, and a chance to greet old friends and network with new ones.
Long Beach, Calif., is perhaps best known as the retirement home of the legendary cruise ship Queen Mary, which is permanently moored there and is currently an operating hotel and museum. But on Sept. 11-12, Long Beach hosted some of the forging industry’s best and brightest technical people, industry professionals, suppliers and educators at what was FIERF’s 32nd Technical Conference.
Germany’s SMS group won the German Design Award in the “Industry” category for an additively manufactured spray head used to cool dies in the forging industry. The award recognizes innovative products and projects and the companies or individuals who have fabricated and designed them. In this case, it was not only the spray-head component that was noteworthy, but also that additive-manufacturing (AM) techniques were used to produce the part.
New process development or the redesign of an underperforming job gives engineers a chance to investigate process influences and design alternatives. Examples of how process simulation has been used in design-optimization projects are detailed.