FORGING NEWS

Sheffield Forgemasters Order 7 New Heat Treat and Forging Furnaces

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Following a formal process, Sheffield Forgemasters have placed an order of over $25 million for seven new furnaces — 3 forging and 4 heat treat — for the company’s proposed 14,000+ ton forging line. The large, open die forge will replace the company’s existing forging press and will complement its smaller press to serve defense and commercial markets.

Andritz, a company with North American locations, will supply the furnaces which will have up to 1,102 tons of capacity and will have rail-mounted car-bottoms which can roll in and out for the loading of ultra-large components.

“The furnaces will be the mainstay of our new heavy forging line, delivering both heat-treatment and main forging heating cycles, using the latest burner technologies for optimum efficiency and heat control," commented Steve Marshall, manufacturing transformation director at Sheffield Forgemasters. “New innovation in furnace technologies includes dual-fuel burners which can switch to hydrogen if the technology to move away from natural gas becomes viable."

Main photo l to r: Roman Mueller-Huenervogt from Andritz Metals and Steve Marshall from Sheffield Forgemasters, sign the furnaces contract.

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FAC Awarded for Aerospace Applications Forging Line

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Jiuli has awarded the final acceptance certificate (FAC) for a hydraulic radial forging line to a metals industry technology supplier with North American locations. The plant has a press force of 18 MN for each of the four press cylinders, which will allow sophisticated materials for the aerospace industry to be forged.

"The new SMX forging line enables us to manufacture our products in a highly cost-efficient way. The high productivity and the wide range of products give us the necessary flexibility to respond quickly to changing demands," commented Luo Tongwei, project manager at Jiuli.

In addition to the SMX 900 / 18 MN as the core machine, the plant comprises two fully synchronized eight-ton forging manipulators and equipment for loading and unloading as well as for cutting, marking and cooling of forged bars. SMS group manufactured the plant to provide a forging strategy that is calculated on the basis of a comprehensive material database as well as the preset machine, material, geometry, and product-related parameters.

“SMS group has enjoyed a close working relationship with Jiuli for over ten years and has supplied them with different types of equipment during this period. We are looking forward to the further fruitful cooperation”, says Jia Hui, senior sales manager at SMS group.


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Heat Treated Forging Tools Get New Quench Tank

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A forging tool manufacturer will receive an agitated heated oil quench tank to be used post-heat treatment in order to set hardness. Tools such as nippers and ladles -- critical components in the foundry and in forging equipment -- are heat treated to the required hardness and then quenched in oil to set that hardness.

The L&L Special Furnace Co. small model QTO1224 heated oil quench tank holds 65 gallons of oil and can quench parts from 50 to 75 pounds. The quench tank oil is agitated by an impeller with a ½ HP explosion-proof motor and is heated with a 4.5 kW immersion heater to maintain the oil at a slightly elevated temperature to help eliminate oil flashing and fire potential.


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Perryman Company Orders 2 Forging Systems

HTD Size-PR LogoAmerican titanium producer Perryman Company, in Houston, PA, has placed an order for the supply of two forging machines: a high-speed open-die forging press in the pull-down design and a hydraulic radial forging machine with two forging manipulators as well as the order and production control system for the entire forging line. The titanium materials are intended for parts in the aerospace industry and for medical applications.

The open-die forging press from SMS group will be used to forge cast titanium billets first to the required size. After that, they can be finish-forged in the radial forging machine to produce bars – round, square or flat – up to a maximum length of 14,000 millimeters.

Dr. Thomas Winterfeldt
Head of Forging Plants
SMS Group
SMS Group

"We see strong growth in the aerospace industry and medical sector," emphasized Frank Perryman, president and CEO of Perryman Company. "This [new forging line] enables us to produce forgings for turbines and safety-relevant structures that comply with our high quality standards."

"With the whole SMS plant package, including digitalization tools and technology packages, Perryman is able to increase its production efficiency and maintain consistent quality levels," said Dr. Thomas Winterfeldt, head of forging plants at SMS group.

The forging line is scheduled to go on stream in Q1 2024.


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Matrix Forgings Manufacturer Commissions Sealed Quench Chamber Furnace

A Polish manufacturer of high-quality matrix forgings, construction connectors, and manual tools manufactured with their own forgings recently commissioned a multipurpose sealed quench chamber furnace to expand their current line of equipment.

Jarosław Talerzak, VP, Thermal Heat Treatment Furnace Systems at SECO/WARWICK

SECO/WARWICK will deliver the fully-automated furnace, a CaseMaster AFS, which is capable of a wide variety of processes but particularly carbonizing, gas carbonitriding and pure hardening, to KUŹNIA Sułkowicie S.A.. The equipment is intended for thermal and thermo-chemical treatment in a controlled endothermic atmosphere.

“We have been cooperating with SECO/WARWICK for more than 10 years. A decade ago, we purchased and implemented a process line for thermal and thermo-chemical treatment with a chamber furnace type CaseMaster AFS 10E,” said Marcin Szafrański, MSc. Ing., Commercial Director at “Kuźnia” Sułkowice S.A. The main customers for the products of KUŹNIA Sułkowice S.A. are the leading European and Polish manufacturers operating in the construction, automotive, power engineering, machinery, and mining industries.

“The appropriately selected production process guarantees the quality of forgings. Thanks to many years of experience in the production of heat treatment equipment, we perfectly understand our customers’ needs, which enables us to propose and help in selecting the most optimum solutions that meet market expectations,” said Jarosław Talerzak, VP, Thermal Heat Treatment Furnace Systems at SECO/WARWICK.

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Gyro Stabilizer Finished with Heat Treating at Texas Forge

Seakeeper Gyro Stabilizer

A closed die forging company, headquartered in Ellwood City, Pennsylvania, recently launched a new marine product line for a gyro stabilizer designed to improve the boating experience by eliminating boat roll, the rocking motion that causes seasickness, fatigue, and anxiety.

The Ellwood Closed Die Group introduced the line for the gyro stabilizer developed by Maryland-based Seakeeper, which also includes several finish-machined flywheels that are assembled into the gyro stabilizers. From start to finish, Ellwood Texas Forge Navasota (ETFN), located in southeast Texas near its sister company, Ellwood Texas Forge (Houston), utilizes the entire Ellwood Group supply chain to manufacture the flywheels. Raw material melted at Ellwood Quality Steel (EQS) and procured from Ellwood City Forge (ECF) is heated and forged on various pieces of equipment within the ETFN facility to produce the near net shaped forgings. After heat treatment and processing, the forging is then rough machined, non-destructively tested for part quality and finish machined to extremely tight tolerances.

Both Texas-based forge facilities provide in-house heat treatment, along with die sinking, cutting, testing and machining capabilities to serve the aerospace, construction, defense, general industrial, marine, mining, oil & gas, and power generation markets.

Seakeeper is based in California, Maryland, with locations in Europe and Asia.

Photo caption: “How It Works: Inside a vacuum encapsulation, a flywheel spins at speeds of up to 9,700 rpm. When the boat rolls, the gyro tilts fore and aft (processes), producing a powerful gyroscopic torque to port and starboard that counteracts the boat roll.”

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Specialty Materials Invests in Aerospace Iso-Thermal Forging, Heat Treat Capacity

A global manufacturer of technically advanced specialty materials and complex components recently announced investment toward its iso-thermal forging and heat treating capacities to satisfy growing demand from the aerospace jet engine market.

CEO of Allegheny Technologies Inc. (ATI), Rich Harshman, CEO of Allegheny Technologies Inc. (ATI), announcing the expansion of ATI’s iso-thermal forging and heat treating capacities to satisfy growing demand from the aerospace jet engine market.  Photo credit: Tony Bettack, WTMJ, Twitter

Allegheny Technologies Incorporated (ATI), headquartered in Pittsburgh, Pennsylvania, will self-fund approximately $95 million, representing two projects: a fourth iso-thermal press and expansion of heat treat capacity. Both will take place at the company’s iso-thermal forging center in Cudahy, Wisconsin. ATI expects the projects to be completed in 2020 and fully qualify for aerospace-related production.

“We continue to invest in our advanced forging capabilities in support of our aerospace customer’s ramp-up of next-generation jet engine production. Once completed and fully qualified, this critical growth project will enable us to meet the increasing production requirements for existing long-term agreements with our engine OEM partners,” said Rich Harshman, ATI’s chairman, president, and CEO. “Iso-thermal is the most technologically advanced forging method available today and ATI’s ongoing leadership in this area is further solidified by this significant investment.”

“This investment, along with our recent nickel-based superalloy powder expansion in Monroe, NC, will enable the High-Performance Materials and Components (HPMC) segment to meet its longer-term financial goals by increasing our capacity to produce technologically advanced powder-to-iso-thermally-forged jet engine components,” said John Sims, Executive Vice President, HPMC Segment.

 

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Rebuilt Rotary Furnace Increases Capacity for Canton Forge

An Ohio-based forge which specializes in precise and durable forgings for aerospace, energy, and transportation markets recently commenced production with a rebuilt rotary furnace designed to service and increase heating capacity for some of its largest hammers.

The furnace was rebuilt in-house at Canton Drop Forge (CDF) in Canton, Ohio, and has North American high-velocity tempest burners. Another furnace will be rebuilt in 2018 to increase the heating capacity for its oilfield forging cell.

CDF’s unique ability to rebuild furnaces in-house advances heating capacity and efficiency, producing forgings used in critical applications with zero tolerance for failure. Home to some of the industry’s largest drop forging hammers in its 241,000 square foot manufacturing facility, the company operates 13 forging hammers and can produce forged parts up to 3500 lbs.

In February, Canton Drop Forge was acquired by Park Ohio, an international supply chain management outsourcing company based in Cleveland.

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Ellwood Forge Heat Treat Location to Expand Office Facilities

 

Source: EllwoodCity.org

 

Ellwood City Forge (ECF), a steel and heavy metals manufacturing group in Ellwood City, Pennsylvania, with heat treating facilities in multiple locations, recently launched construction on the renovation and expansion of its office facilities at the same location on Second Street where the company broke ground and has been in operation since 1910.

The project will include renovation of ECF’s existing building and construction of a new, adjoining building and continue to house the offices of parent company Ellwood Group, adjacent to manufacturing operations, including bloom processing. Heat treating, forging, and machining operations are located at two of ECF’s other six plants — New Castle, Pennsylvania, and Corry, Pennsylvania.

Ellwood City Forge supplies open-die forgings for a broad range of applications, including oil & gas, power generation, mining, industrial machinery, metal processing, power transmission and gearing, aerospace, infrastructure and construction, defense, and shipbuilding.

Read more: “Groundbreaking — New ECF Office”

Left to Right: Evan Fennell, Engineer and Project Manager, ECF; Ray Santillo, Executive Director, EC Chamber of Commerce; Steve Paxton, Architect, Franus Architectural Associates; Denny Boariu, Product Specialist, Ellwood City Forge/Chamber of Commerce Representative; Tony Court, Mayor, Ellwood City; Anna Barensfeld, Shareholder, Ellwood Group; Bill Nardone, VP of Operations, Ellwood City Forge; Dan Franus, Architect, Franus Architectural Associates; Phil DiMarco, Principal, DiMarco Construction

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Ellwood Group Acquires Gulfco Forge Company

  Source:  ForgingMagazine.com

Gulf Coast Machine and Supply Company (Gulfco) utilizes forging equipment including a 3,500-ton open-die press, a 2,000-ton press, 10,000-lb. hammer, and several ring mills.  It also has heat-treating, finish machining, and product testing capabilities. The Ellwood Group has purchased Gulfco and will operate it under EGI.

Read more: Ellwood Group Acquires Gulfco Forge by Robert Brooks

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