Onex Inc. of Erie, Pa., designed and manufactured a front-loading forge furnace for a leading North American forging company. The furnace, one of the largest of its kind in North America according to Onex, has workspace dimensions measuring 26 feet wide x 20 feet deep x 14 feet tall. It features an engineered lintel system that provides a longer life than traditional refractory lintels. The furnace also has a combination module roof, which is less costly than a full polycrystalline lining and does not shrink like traditional ceramic-fiber containing zirconia.
Digital design modeling can be reliably used as a design aid in the thermomechanical processing of forged parts. In this analysis, models were used to simulate metal flow and thermal behavior while considering the possibility of cracking hazards and the prediction of structural behavior in the heat-treated steel. The simulation reduced scrap by 50%, eliminated potential defects and allowed the forging to be produced on a smaller press.
Patriot Forge Co. (Ontario, Canada) depends on advanced high-density polyethylene (HDPE) cooling towers to maintain optimum bath temperatures for quenching metal forgings and cooling hydraulic systems.
December 7, 2018
The forging industry has achieved an impressive place in the North American industrial economy by producing components with unique benefits that are difficult to duplicate by any other metalworking process.
Lefere Forge of Jackson, Mich., will be closing on or about Dec. 1 after 89 years in business. The family-operated company is ending operations due to financial and labor issues. Lefere Forge’s website has been deactivated, but according to local reporting the company sent out an email on Nov. 1 to its customers stating that “…the last several years have been challenging financially, and a continuing labor shortage has not allowed us to operate the plant efficiently.” Approximately 60 employees will be displaced.
SECO/WARWICK will supply a multipurpose sealed quench-chamber furnace to Kuznia Sulkowicie SA, a Polish manufacturer of matrix forgings, construction connectors and manual tools. The furnace is designed for heat treatment (such as gas carbonitriding and pure hardening) in a controlled endothermic atmosphere. The fully automated operation of the furnace is its unique advantage. Personnel are only required to load and unload the work after treatment. The cycle and product transfer is completely automated.
Weldbend Corp., a manufacturer of carbon steel fittings and flanges, started installation on what it says is the largest cold-form Tee-Press in the Americas and Western Europe at its manufacturing facility in Argo, Ill. The new press, which weighs 1.2 million pounds and contains 5 miles of wire, will significantly expand Weldbend’s forging capabilities. It will be able to forge up to a 20-inch XS Tee with material grades including Y70. The company can currently cold forge a 6-inch Tee. Weldbend’s products are used in mechanical systems and oil-and-gas pipelines.
Arconic introduced an advanced titanium alloy called ARCONIC-THOR that is designed for higher-temperature applications in next-generation aero engines and adjacent structures. The new patented alloy is nearly 50% lighter than incumbent nickel-based superalloys, driving cost savings and fuel efficiency for customers and helping Arconic capture growing demand for advanced aero engine and airframe materials. ARCONIC-THOR can be produced as sheet, plate, foil, billet, rolled rings, forgings and extrusions. It is formable (cold, hot, superplastic), heat treatable, forgeable and weldable.
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.
Improvements in steel manufacturing processes have yielded advancements in the purity of steel that, in turn, yield higher-quality end-use products. Clean steel is produced by judiciously controlling parameters in melting, refining, degassing and casting operations. The demand for clean steels will continue to increase due to the global push for energy efficiency and stricter CO2 emission regulations.
Steel is an amazing material when you consider its versatility. Steel can achieve the needed characteristics for a vast array of end products; it is relatively low cost compared to many other materials; it is endlessly recyclable without loss of property; and it can be mass produced, with annual global production of over 1.5 billion tons.
The sawing of bar stock into billets is one of the first steps in many forging processes, yet for some reason the bandsaw operation and equipment often do not get the attention they deserve. This article discusses how to improve your bandsaw’s operational and performance efficiency.
If there is one machine on your manufacturing floor that isn’t getting the attention it deserves, it’s most likely your bandsaw. For many forging houses, it is a bottleneck at worst and ignored at best.
Check out the December 2018 issue of FORGE, featuring our cover story that showcases Weber Metals' New 60,000-Ton Hydraulic Press. Other features include "California Hosts 32nd FIERF Technical Conference", "HDPE Cooling Towers Take the Heat", and much more.