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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.
The productivity of a forge shop can be greatly affected by the efficient flow of workpieces through the plant. Solutions to handle workflow range from motorized manipulators to rail-mounted systems to overhead manipulators. For most applications there is more than one solution, and an experienced engineer can help you select the right system for your operation. It is important not to be guided by price alone but rather to think in the long term.
On Feb. 8, 2019, Arconic Inc. announced its decision to split itself into two separate companies: Engineered Products & Forgings and Global Rolled Products (GRP). The two businesses will focus on, respectively, the production of finished parts and the production of sheet. The company says it is considering the sale of operations and assets that do not fit its new organizational model. Also, it has reduced its dividend from $.06/share to $.02/share.
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.
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 internal combustion engine (ICE) has been the world’s dominant form of vehicle propulsion for 100 years and counting. However, global regulatory changes focused on emissions reduction, road safety and fuel-economy improvement are increasing the potential for fully electric, zero-emissions vehicles, which will create a significant disruption to this 100-year-old technology.
Researchers at Ohio University conducted a FIERF-funded inquiry to understand what cold deformation did to additive-manufactured (AM) shapes. This understanding is critical to harnessing the advantages of both processes and improving the mechanical properties of AM parts as AM technologies continue to emerge and mature.
Additive manufacturing (AM) has become a specific topic of interest in the general manufacturing community due to its novelty and projected abilities for ground-up automation.
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.
To stay competitive, forgers must continuously integrate advanced manufacturing technologies into their production. Long gone are the days when forging was simply a means of shaping metal.
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.
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