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Open Die Forging Aerospace Application

Have you ever heard of the term “smith forging”? Before all the advancements in tools and technology, forging was performed by a smith using an anvil and hammer to produce and create forged metal – hence, the term. Smith forging, commonly known as open die forging, is a process that involves a hammer striking and deforming a workpiece securely attached to a stationary anvil.

What is Open Die Forging?

Why do Aerospace Companies Prefer Open Die Forging?

The Basics

Open die forging involves the process of forging alloys without having to enclose the workpiece throughout the procedure. In this process, it is required that the operator knows the proper position and orientation of the workpiece to achieve the desired shape.

The dies or surfaces are normally flat in shape. However, there are instances when dies with a specific shape are used for specialized forging. For instance, a die may have a convex, concave, or round surface. It may also be a cut-off tool or a device to form holes.

Advantages of Open Die Forging

Aerospace companies consider the advantages of open die forging before choosing this metalworking process to produce aerospace parts and components. Below are the advantages:

  • Superior strength
  • Better-quality grain size
  • Constant grain flow
  • Enhanced microstructure
  • Improved fatigue resistance
  • Reduced chance of voids

Progressive open die forging techniques are capable of creating multiple shapes notwithstanding the large parts and components used. Simple shapes like rounds, ingots, and bars are easier to produce because of the constant grain flow and improved fatigue resistance.

The most common subjects used for smith forging are steel and related alloys. Nonetheless, other metals can be shaped as desired. These metals include titanium, nickel, and copper alloys.

Industrial or Commercial Aerospace Parts

The following are the parts and components used by aerospace industries that were produced and forged through an open die forging method:

  • Shafts
  • Seamless rolled rings (bearings)
  • Rotor/Propeller Parts
  • Landing gear components
  • Flat bar
  • Flanges
  • Disks

What is Open Die Forging?

Learn More About Open Die Forging Applications

At Ferralloy Inc., our commitment to the industrial and commercial sectors has made us grow bigger. We make sure to give more importance to the quality and satisfaction of our clients. Contact us today to speak with an expert!

Development and Characterization of Ring Rolling

Have you ever wondered how the ball and roller bearing races, pressure valves, pipes, and turbines are made? These metal pieces are produced through a process known as ring rolling. This is a specific category of metal rolling wherein a smaller diameter ring is rolled into a reduced cross-section and an accurate ring of larger diameter. Below are the facts about what ring rolling is, as well as its developments and characterization.

What is ring rolling?

Facts to Know About

What is it?

Ring rolling is accomplished by using two rollers, one idle and one driven. The rollers move on either side of the ring’s cross-segment to create an efficient and precise motion. To guarantee the ring will maintain an unbroken width pattern the entire forming process, manufacturers use an edging roller during the industrial metal rolling process.

What are the Characteristics?

The process will retain the same volume of the metalwork. In this way, the geometric reduction in thickness will be reimbursed entirely because of the upturn in the ring’s diameter. Among the many characteristics, the most notable one is the manufacturing of seamless rolled rings. This procedure is used to produce not only flat rings but also rings that are designed to have different shapes and cross-sections.

Another significant characteristic of this process is that it can produce accurate parts and components with little waste of material. Additionally, the process involves an enhanced grain orientation that provides the metal robust strength appropriate for several applications.

What are the Developments?

This technique is gearing towards the new metalwork process with heightened geometries and more complex cross-section geometries. The applied knowledge gathered through the years by experts is insufficient to estimate the precise interface of various process parameters. Nonetheless, experts and manufacturers can still rely on simulation software to produce an accurate ring rolling model and evaluate the material properties and material flow with accuracy.

What is ring rolling?

Complex Facts About Ring Rolling

When it comes to forging, it is ideal that you get advice from specialists. We know this matter involves intricate and elaborate details. At Ferralloy Inc., we make sure that you are provided with detailed information about the engineered products we offer.

Reasons to Try Seamless Rolled Rings

Many industries use seamless rolled rings. Moreover, it may even surprise you to know that many industries like aviation and food processing use these rings in their regular line of work! So, why do so many companies from opposite paths of industry opt for seamless rolled rings? Let’s find out.

What are seamless rolled rings?

The Exceptional Process and Materials

Process Involved

The forging process starts with a circular metal component. Next, the component is cautiously pierced to create a hollow ring that looks like a doughnut. Then, the ring is moved and processed to recrystallization temperatures. Finally, after the recrystallization process, it is placed onto the idler roll and under pressure, directed towards the drive roll to produce the desired product.

Types of Rolled Rings

There are three main types of rolled rings:

  • Carbon – commonly used for pressure and structural vessel applications
  • Alloy – used for gear and bearing applications in addition to a variety of industrial equipment applications
  • Stainless Steel – mostly used for food and chemical processing applications.

Materials or Components Used

Seamless rolled rings can be made from any forgeable material! Furthermore, these include, but are not limited to:

The ability to create seamless rolled rings out of a wide range of materials is one of the many reasons why so many companies choose to work with them.

What are seamless rolled rings?

Advantages of Using Seamless Rolled Rings

Seamless rolled rings are used by various industries for many reasons. Moreso, some of the common reasons are a broader range of materials, better performance under heat, reduced costs, and greater strength. These rings can be created from numerous forgeable materials, including aerospace metals, carbon, stainless steel, and alloy.

Additionally, unlike the other ring components, it is easier to predict how these rings will react. These rings can maintain their strength despite the fluctuating temperature. To know more about seamless rolled rings, contact Ferralloy Inc. today!