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Forging can measurably reduce material costs since it requires less starting stock to produce many part shapes and can achieve near-net shapes, saving on scrap costs.

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By minimizing the number of components in a fabricated part and enhancing design, Scot Forge can produce parts with increased quality while reducing overall cost and production time.

PRODUCTION EFFICIENCIES

Scot Forge has many different sizes of starting ingots and billets on hand, providing a wide variety of ready-to-forge inventoried grades. Using the forging process, the same part can be produced from many different sizes of starting ingots or billets, allowing for a wider variety of inventoried grades. This flexibility means that forged parts of virtually any grade can be manufactured more quickly and economically.

Forging also can yield advantages in machining, lead time and tool life. Savings come from forging to a closer-to-finish, or near-net, size than what is capable by alternative metal sources such as torch cutting plate or boring bar. Therefore, less machining is needed to finish the part, with the added benefits of shorter lead times and reduced wear and tear on your equipment.

REDUCED REJECTION RATES

Often discovering a defect in a cast part doesn’t happen until a part has been on a machine for hours, which can be a headache. But, when this happens to multiple parts it can be a nightmare. It takes time and money to replace parts, puts hours on the machine and increases labor costs, not to mention the lost opportunity cost. Because forging has a 3:1 minimum reduction, porosity and piping are eliminated yielding improved structural integrity. Coupled with a weld-free design, forging can dramatically reduce part rejection. 

STEEL CASTINGS AND FORGINGS

Steel castings, forgings and extrusions are used in a number of different industries. As a durable and dependable material, steel is suitable for use in challenging environments that require high strength applications.

It allows for various heat treatment procedures that can improve its yield and tensile strength, as well as adjust its hardness and ductility for specific applications. It is also well known for its outstanding versatility that allows it to readily accommodate all types of shapes.

Steel remains lower in cost than most non-ferrous materials used for manufacturing and industrial purposes and comes in numerous alloys that display a wide variety of properties.

Types of Steel Alloys

Carbon Steel

There are different types of carbon steel on the marketplace today. Carbon steel, the most commonly used alloy, contains carbon as the major alloying element. Carbon exerts the strongest influence in determining the properties of a steel alloy, especially the hardness and strength levels of the material.

Typically, carbon steels fall into three distinct categories:

High carbon steel: High carbon steels possess a carbon range between 0.61% and 1.50%. These steels prove difficult to cut, bend or weld and may become brittle.

Medium carbon steel: Medium carbon steels typically display a carbon range of 0.31% to 0.60%, and a manganese content ranging from a low of .060% to a high of 1.65%. Much stronger than low carbon steel, medium carbon steel proves more difficult to form, weld and cut.

Low carbon steel: This category typically contains 0.04% to 0.30% of carbon content. It fits a variety of shapes, from flat sheets to structural steel beams. A steel mill may add other elements to low carbon steel to produce specific desired properties.
 

Alloy Steel

Steel can be alloyed with elements other than carbon to produce specific properties that are not found in regular carbon steel. Some of the most common alloying elements include: 

• Manganese

• Nickel

• Copper

• Aluminum

• Cobalt

• Silicon

• Titanium

• Chromium

• Tungsten

• Molybdenum

• Silicone

• Phosphorus

• Vanadium

• Niobium

These elements are added to steel in varying proportions and combinations in order to make the material take a wide array of different physical properties. This includes: increased hardness or strength, improved corrosion resistance, improved ductility, improved machinability, and better cutting ability. Steel alloys also allow manufacturers to gain more control over metal grain size, the speed of hardening, stability at high or low temperatures, and even durability (wear resistance).

Which Steel Alloy Is the Best Choice for My Component?

Understanding the properties of each of the alloying elements and their effects is important for selecting an alloy that will best meet the requirements of the part that needs to be manufactured.

The company is the world’s best shaft forging manufacturer supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

To find an alloy suitable for your component, please consult the steel grade table below. For further details and questions, please do not hesitate to speak with one of our sales representatives. Simply outline your design issues and the goals of your project and a company team member will help you select the best steel alloy for your purposes.

Typical steel alloys include, but are not limited to, these grades:

GRADE 1020: cold headed bolts, axles, general engineering parts and components, machinery parts, shafts, camshafts, gudgeon pins, ratchets, light duty gears, worm gears, spindles;

GRADE 1040: machinery parts, couplings, crankshafts, cold headed parts;

GRADE 1050: machinery parts;

GRADE 1095: springs or cutting tools which require sharp cutting edges;

GRADE 1137: tools, springs;

GRADE 1141: shaft, machined parts;

GRADE 4130: general purpose, high strength steel shafts, gears and pins, welded tubing;

GRADE 4140: general purpose, high strength steel shafts, gears and pins;

GRADE 4150: general purpose, high strength steel shafts, gears and pins;

GRADE 4340: power transmission gears and shafts;

GRADE 6150: shafts, gears, pinions;

GRADE 8620: medium-strength applications such as camshafts, fasteners, gears, chains/chain pins;

GRADE 8760: tools, springs, chisels;

Understanding the Steel Numbering Systems

The modern steel industry uses two numbering systems to help identify types of alloy steels. Developed by the American Iron & Steel Institute (AISI) and the Society of Automotive Engineers (SAE), both of these systems are based on four-digit code numbers that identify the base carbon and alloy steels.

The first two digits in the four-digit series relate to the type of material selected. The initial digit ranges from 1 through 9 to identify the type of steel involved:

1xxx Carbon steel

            10xx Plain carbon steels (containing 1.00% manganese maximum)

            11xx Resulfurized carbon steels

            12xx Resulfurized and rephosphorized carbon steels

            15xx Non-resulfurized high-manganese (up-to 1.65%) carbon steels

2xxx Nickel steel

3xxx Nickel-chromium steel

4xxx Molybdenum steel

5xxx Chromium steel

6xxx Chromium-vanadium steel

7xxx Tungsten-chromium steel

9xxx Nickel-chromium steel

The second digit indicates the concentration of the significant element impacting the properties of the steel, expressed in percentiles. Finally, the last two digits represent the percentage (0.00%-0.99%) of added carbon.

For example, the number pair 1018, or “10” and “18”, designates Carbon Steel with 0.18% Carbon added. The number pair 2130, or “21” and “30”, means Nickel Steel Alloy containing 1% of of nickel and 0.30% of carbon. Some manufacturers also insert an “L” into the code to indicate the addition of lead or “B” to indicate the addition of boron.

Contact Bunty LLC Today

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