forging magazine
DESCRIPTION
Forging processTRANSCRIPT
FORGINGA Penton Publication July/August 2012
Visit us on the web at www.forgingmagazine.com
INSIDE:
UNIVERSAL STAINLESS
STARTS RADIAL FORGE
I PG.6
PROTECTION AGAINST
HEAT-TREATING COSTS
I PG.18
NEW HYDRAULICS FOR
PRECISION PRESS CONTROL
I PG.32
FINISHING STRONG
The approach of IMTS highlights forgers’ embrace of emerging capabilities in ‘manufacturing technology.’
I PG.24
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“Ask for a weld shop tune up”
2 I FORGING I JULY/AUGUST 2012
ON THE COVER:'HVLJQ�E\�%LOO�6]LODJ\L��
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C O N T E N T S
FORGING (ISSN 1054-1756) is published in January/February, March/April, JULY/AU-GUST, July/August, September/October, and November/December by Penton Media Inc., 9800 Metcalf Ave., Overland Park, KS 66212-2216. Periodicals postage paid at Shawnee Mission, KS and additional mail-ing offices. Printed in the U.S.A. Copyright (c) 2012 by Penton Media Inc. Canadian GST# R126431964, Canadian Distribution Sales Agreement No. 40026880. Subscrip-tions: Solicited at no charge from qualified persons in the forging industry. All oth-ers pay $49 for one year, $10 per issue, in the U.S.; $59 for one year; $15 per issue in Canada. International subscriptions are offered at $79 for one year, $20 per issue. Send subscription payment to: FORGING,
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JULY/AUGUST 2012 I VOL. 22 , NO.4
Editor’s Note .......................................... 4
Industry News ........................................ 6
FIA News .............................................12
Newsmakers .........................................14
New Products ........................................26
Product Express .....................................29
Advertiser Index .....................................31
Business Staff .......................................31
Looking Ahead ......................................32
HEAT TREATING
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ROBERT E. BROOKS I EDITOR
THEY BELIEVE THAT IF THEY MAKE IT SUFFI-CIENTLY COMPLEX, OR SCARY, WE’LL GIVE THEM MORE MONEY WITHOUT DEMANDING THAT THEY MANAGE IT RESPONSIBLY.
4 I FORGING I JULY/AUGUST 2012
EDITORIAL STAFF
E D I T O R
Robert E. Brooks
G R A P H I C S E D I T O R
Bill Szilagyi
M A N U F A C T U R I N G &
S U P P L Y C H A I N G R O U P
C O N T E N T D I R E C T O R
Patricia Panchak
EDITORIAL-
ADVISORY BOARD
Carola Sekreter
Forging Industry Association
Alvin M. Sabroff
Metalworking
Consultant Group
Dr. Rajiv Shivpuri
The Ohio State University
Dr. Chester J. Van Tyne
Colorado School of Mines
FORGING
1300 East Ninth Street
Cleveland, OH
44114-1503
Tel. 216-696-7000
Fax 216-696-7932
www.forgingmagazine.com
E D I T O R I A L
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I N D U S T R Y N E W S
UNIVERSAL STAINLESS STARTS RADIAL FORGE
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6 I FORGING I JULY/AUGUST 2012
AMERICAN AXLE STARTS NEW PLANT IN INDIA
American Axle & Manufacturing Holdings Inc. marked the opening of its new
Chennai Manufacturing Facility (CHMF) in southeast India in early August. The
new operation produces front and rear axles for commercial vehicles, for Asian
distribution. AAM is a global manufacturer of driveline and drivetrain systems, as
well as related components and modules, and
chassis systems for trucks, SUVs, passenger
cars, and crossover vehicles.
“We are extremely pleased to celebrate the
grand opening of AAM`s third regional manu-
facturing operation in India,” stated John J.
Bellanti, AAM executive vice president, World-
wide Operations. “The Chennai Manufacturing
Facility will allow us to leverage AAM`s track
record of world-class quality, delivery, reliability and outstanding warranty perfor-
mance while furthering AAM`s global expansion in emerging markets.”
AAM’s other Indian production sites are at Pune, where it produces axle assem-
blies for heavy commercial vehicles produced in India and abroad; and at Pantna-
gar, where it produces axle assemblies for light trucks, passenger cars, and SUVs
for the Indian market. The latter plant is a former joint venture with Sona Koyo Ltd.,
now wholly owned by American Axle.
The group also has an engineering center at Pune, where it develops products
and IT services for its regional customers.
“Profitable growth in India is a key component of AAM`s global business strat-
egy,” according to managing director - AAM India, Anand M. Ganguly. “Chennai
Manufacturing Facility reflects AAM`s commitment to India while allowing us to
provide advanced-technology products for current and potential new customers
throughout the region. The facility is strategically located in close proximity to our
OEM customers.”
American Axle has forging and other manufacturing plants worldwide, including
in Indiana, Michigan, Ohio, and Pennsylvania, as well as Brazil, China, Germany,
Japan, Luxembourg, Mexico, Poland, South Korea, Sweden, Thailand, and the U.K.
Your Source For Large Diameter High TempCorrosion Resistant Alloys
We have the metals you specify when high strength
and corrosion resistant solutions are needed.
O’Neal High-Performance Metals Group
Hartford, CT 800.243.4344
Greenville, SC 800.243.4344
Houston, TX 281.669.0975
Los Angeles, CA 800.337.3766
www.AerodyneAlloys.com
Call today for immediate support:
Super Alloys for components used in hostile environments. We stock Nickel, Cobalt and Titanium alloys for Just-In-Time delivery.
Choose from a broad range of diameters so you machine less. Every pound fully certified. Ships in 24-hours of in stock order.
You can’t make parts if you don’t have the metal.
Military Commercial
Oil & Gas PowerGen
Nickel, Cobalt, Titanium, Stainless, Alloy X, NACE, GE Specs
I N D U S T R Y N E W S
8 I FORGING I JULY/AUGUST 2012
ENERGY-SAVING EARNS $200K FOR MERITOR AXLE PLANT
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I N D U S T R Y N E W S
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FORGING NEWS BRIEFS
Accuride Corp. will deploy Plex Sys-
tems’ software-as-a-service (SaaS)/cloud
enterprise resource planning (ERP) solution
across its operations. As detailed by Plex,
Accuride will consolidate seven separate
systems running more than 200 applications
as it implements the Plex Online ERP system.
Forgital Group, Vicenza, Italy, was
awarded the Roll-Royce GTSC Supplier of
the Year Award for 2011. Forgital produces
titanium forgings for the Fan Case Module
of the Trent XWB engine, which will power
the new Airbus A350 XWB family of aircraft.
Roll-Royce GTSC (Gas Turbine Supply Chain)
has over 500 suppliers globally, collaborating
on critical parts, and the award reflects a
positive working relationship and strategic
alignment with Rolls-Royce standards.
Alcoa entered into new, multi-year sup-
ply agreements with Airbus for its aerospace
aluminum sheet, plate, and hard-alloy ex-
truded products using Alcoa’s aluminum-
lithium and other alloys.
The Steel Market Development In-
stitute introduced a new Bar Steel Fatigue
Blog — www.autosteel.org/barfatigueblog
— an online tool for automotive engineers
looking for fatigue innovations and informa-
tion. Based on SMDI’s Bar Steel Fatigue
Database is available to open participation
by steel and ground vehicle OEM and sup-
plier design engineers, powertrain/chassis
engineers, materials engineers, application
engineers and FEA simulation experts, as
well as current users of the Bar Steel Fatigue
Database.
0UK\J[VOLH[��0UJ����4HKPZVU�/LPNO[Z��40��<:(
;LS!�������������� � ����^^ �̂PUK\J[VOLH[�JVT
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[OH[�^L�KV��HUK�SVVR�MVY^HYK�[V�ZLY]PUN�[OL�TL[HSZ�HUK�TH[LYPHSZ�PUK\Z[Y`�MVY����TVYL�
A GIRARD and GLAMA partnership means more than nine decades of
combined expertise in the forging Industry. Our companies compliment
one other and by combining forces, we can offer even more complete
solutions to the challenges faced by forging operations worldwide.
GLAMA expertise lies in specialized mobile, stationary and automatic
equipment for open and closed die forging, aluminum, rolling and
steel making industries.
GIRARD Engineering specializes in the design and implementation
of state-of-the-art automation and control systems for the forge.
We can retrofit your existing equipment or provide a complete, custom
state-of-the-art solution designed to keep you competitive in today’s
tough, always changing market conditions.
In addition to providing the most up-to-date engineering and
technology we are proud of our after sales support and service. In fact,
in some cases we can even provide same day service.
Let us show you. Whatever your operational challenge, GIRARD will tailor a custom
solution, on time and on budget. Call 440-243-2212 or email us at
[email protected] to see how GIRARD Engineering can help
you automate your forge.
A POWERFUL PARTNERSHIPIN NORTH AMERICA & MEXICO
GIRARD Engineering and GLAMA have joined forces to provide even more complete turnkey solutions for your forging operations.
+
Panel Shop
GIRARD Engineering / 8150 East Dow Circle / Strongsville, OH / 44136 USA / P: 440-243-2212 / E: [email protected] GirardUSA.com
F I A / F I E R F N E W S
12 I FORGING I JULY/AUGUST 2012
FIERF AWARDS
16 FINKL
SCHOLARSHIPS
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PITTSBURGH
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FIA Calendar
First Line Supervisory
Development Seminar
September 24-27, 2012
Cleveland
Theory & Applications of
Forging & Die Design School
October 29-November 1
Cleveland
Hammer Maintenance
Workshop
October 16-17, 2012
Cleveland
Fall Meeting of Members
October 22-23, 2012
Las Vegas
Forge Fair 2013
March 26-28, 2013
Columbus, OH
FIA 100th Anniversary
Annual Meeting
May 4-6, 2013
San Diego
For information on FIA events, visit
www.forging.org, or contact George
Layne, [email protected]
the complete range for the forging industry
Oststrasse 1D-77694 KehlGermany
Phone +49 7851 93 76-0Fax +49 7851 93 [email protected]
www.presstrade.com
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14 I FORGING I JULY/AUGUST 2012
Beyer
Mensing
Oates
The International Conference on
Ingot Casting, Forging, and Roll-
ing drew 450 participants for over
100 presentations and exhibits.
O U R P A S S I O N F O R M E T A L S
For more than 70 years, Elotherm has been a leader in
the design and production of high-performance induction
heating systems. Our solutions are used in automotive,
aerospace, military, mining, construction, energy,
agriculture, steel, and tube & pipe applications, as well
as in many others. With a North American team that
services the United States, Canada and Mexico, Elotherm
is ready to help.
Whether you’re heating powertrain components, billets,
bars, tubes or other shapes, our technology gives you
superior quality for:
– Heating
– Welding
– Heat Treating
– Induction Surface Hardening
Adding depth to our capabilities is the recent consolidation
with Tech Induction, North America’s largest coil design
and repair facility, leading the way in developing innovative
solutions that help customers streamline their processes.
This pairing makes us a one-stop shop for service that’s
available 24/7/365 to help ensure the reliability of your
critical operations.
Put Our Team on Your Team with a Lineup
of Induction Heating & Heat Treating Solutions
Our services include:
– Coil Management
– Field & Factory Service
– Remanufacturing & Rebuilds
– Emergency & Routine Repair
– Inspections & Documentation
With expansive facilities near Detroit and Indianapolis
housing design and production teams that set the industry
standards for innovation, dependability, quality and
service, Tech Induction’s dedicated team of experienced
professionals strengthens our position as a vertically
integrated OEM.
Together, Elotherm and Tech Induction have the ability
to give you an unmatched combination of technology,
equipment and support that helps you stay competitive
in these challenging times.
If you play to win, call George Burnet at 724.553.3471,
e-mail [email protected] or visit
www.sms-elotherm.com
E X C E L L E N C E I N M A N U F A C T U R I N G
Elotherm North America
210 West Kensinger Drive, Suite 300
Cranberry Township, PA 16066
P: 877.735.6843
www.sms-elotherm.com
Tech Induction
13129 23 Mile Road
Shelby Township MI 48315
P: 586.469.8324
www.techinduction.com
Tech Induction leads the way with
innovative solutions that combine
technology, engineering expertise
and service to help customers
optimize their processes and
improve bottom line results.
SMS Elotherm’s EloCrank™
series was designed for hardening
crankshafts. EloFlex™ series
equipment hardens steering, axle
and gear components, as well
as many other products.
Tech Induction’s 50 dedicated team
members are committed to meeting
the needs of our customers.
The consolidation of Elotherm and
Tech Induction is an outstanding
example of the whole being greater
than the sum of the parts. While
each company has a different set of
complementary strengths, we share
a set of common beliefs, including:
– Innovative thinking and engineering
excellence are the keys to growth
– Every customer deserves an ideal
solution that’s tailored to the
specific application
– A work environment that encourages
ongoing teamwork is vital to the success
of our customers and ourselves.
Elotherm and Tech Induction. Two great
companies are now a single source for all
of your induction heating needs.
The professionals at Elotherm
and Tech Induction use their technical
know-how to help our customers
improve productivity and quality.
See us at
INDUCTIONHEAT
TREATINGCOIL
18 I FORGING I JULY/AUGUST 2012
BY S.P. SHENOY
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HEAT TREATING COST REDUCTIONSDue to Protective Coatings
Figure 1. The gear-end section of a crankshaft is
prone to quench cracking. A practical technique for heating any kind of steel without the problems associated with oxidation and decarburization.
FORGINGMAGAZINE.COM I FORGING I 19
O2
+ 2 Fe ≠ 2 FeO
O2
+ 4 FeO ≠ 2 Fe2+O
3
CO2
+ Fe ≠ CO+FeO
CO2
+ 3 FeO ≠ Fe3O4+CO
Table 1. Oxidation
O2
+ C ≠ CO2
O2
+ Fe3C ≠ 3 Fe+CO
2
CO2
+ C ≠ 2 CO
CO2
+ Fe3C ≠ 2 CO+3Fe
H2O
+ Fe
3C ≠ CO
+ H
2+3 Fe
Table 2. Decarburization
Scrap¶ ¶
Ability to salvage the rejected
components
Salvage by Re-Heat Treatment
Using protective
Coating
Rejected Components(Heat Treated)
(Metallurgical Reasons)
Diagram 1.
Understanding Oxidation and Decarburization
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HOT FORMINGelbow, tee, reducer, cap, stub end, return bend grades:aisi-304, 304l, 316, 316l, 321, 321h, 347, 347h
¶ ¶Solution
Annealing
¶ ¶
¶ ¶Buffing
Buffing can be eliminated in many
cases. hence quicker deliveries
¶ ¶
¶ ¶
PicklingPickling time is
reduced by 75%
Pickling
Inspection
Shipping
Benefits of using coating in
processing of stainless steel pipe
fittings.
Conventional Coating
Method Process
HOT FORMINGelbow, tee, reducer, cap, stub end, return bend grades:aisi-304, 304l, 316, 316l, 321, 321h, 347, 347h
SolutionAnnealing
Inspection
Shipping
Diagram 2.
20 I FORGING I JULY/AUGUST 2012
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SURWHFWLQJ�WKH�JHDU�HQG�DQG�VWHP�SRUWLRQ�
Conventional Coating
Method Process
Steel Plates
¶
¶
¶
Shot Blast
¶
¶
¶
Anneal Anneal after using protective coating
Dispatch
Productivity improvement due to
substantially reduced scaling in heat
treatment of steel plates.
Steel Plates
Light Shot Blast
Shot Blast
¶Dispatch
¶
Shot Blast
Diagram 3.
Figure 4. For pressure vessels,
critical valve areas may be protected
during heat treatment. In this
example, coating was applied to the
white colored areas.
Figure 2. The stem portion of a
steering knuckle is prone to quench
cracking.
Figure 3. A fully machined spindle
re-heat treated by applying anti-scale
compound. No scaling observed, and
the aesthetic appeal is maintained.
Type of furnace used: ................... Box type, electric.
Test Coupon dimensions : ........... 300 mm X 100 mm X 10 mm
Grade of steel: .............................. AISI – 1010
Heat treatment cycle: ................... 1000°C / 4 hrs / air cool
% scale loss when not coated: .... 5.52
% scale loss when coated: .......... 0.70
Table 3. Efficacy of Protective Coating.
EHS TODAY’S AMERICA’S SAFEST COMPANIES CONFERENCE
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3 Tracks/3 Keynotes/18 Sessions
❯ Safety & Health
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Who Should Attend:
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❯ Plant Supervisor/Manager
❯ EHS/Safety Director
or Manager
❯ Risk Manager or Director
WHY ATTEND:
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effectiveness
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risk management
approaches to reduce
workers’ comp costs
❯ Network with America’s
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from top workplace labor
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ACT NOWFIRST 100
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Transformational Leadership in Safety
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September 11-12, 2012
KEYNOTE SESSION: THE INSIDERThis panel discussion among current and former OSHA and NIOSH
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inner workings of OSHA and NIOSH and the rule-making process.
Edwin G. Foulke, Jr
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BONUS: IMTS Exhibit Hall Pass Included
22 I FORGING I JULY/AUGUST 2012
Salvaging forgings during re-heating
for hot forging —�5H�KHDWLQJ�RU�UH�ZRUN�
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Figure 5. Pit marks that formed due to scaling during re-heating for re-working
can be observed .
Figure 6. This part was coated prior to re-heating with a protective anti-scale
coating and shows no pit marks, as scale formation was prevented.
29th FORGING INDUSTRYTECHNICAL CONFERENCE
WHO SHOULD ATTENDForging industry CEOs, plant managers, technology directors and managers, plant and chief engineers, engineering managers, metallurgists, professors and principals from the research and associated government agencies are encouraged to attend this conference.
Marriott, Downtown Cleveland at Key Center, OhioSeptember 10-12, 2012
The Industry Technical Conference is designed to showcase the best in forging technology. This year’s conference will be offering 34 papers presented by forging industry experts, international researchers, and individuals from academia. To provide a platform of discussion for both, Newly Applied Technology and Research, and to accommodate the different levels of experience, dual tracks on day 2 will be offered for the first time.
Also offered will be Roundtables for focused discussion on topics of interest. Objective of the conference is to report out FIERF funded research projects and industry collaborative group results; discussion of case studies; provide a forum for students and professors to present their forging research; and provide a networking opportunity between industry, academia and research partners.
For further information and registration details go to: www.forging.org/events/tech-conference
216.781.6260 U www.forging.org
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24 I FORGING I JULY/AUGUST 2012
This EMAG vertical center finishes gears with a combination of
grinding and turning, using two spindles and a turret. It’s an example
of multitask machining — one of the emerging trends in finishing
processes that is changing the scope of activities for forging
operations.
FORGINGMAGAZINE.COM I FORGING I 25
King Awards Competition
New Equipment Digest
The awards honors superior industrial product
innovation and showcases the best new products
program introduced in 2012.
PRODUCT CATEGORIESThe King Awards will recognize Gold, Silver and
Bronze winners in up to 11 categories:
• Assembly/Fastening/Tools
• Controls & Instruments
• Electrical/Electronics
• Facilities/ Maintenance/Plant Operations
• Fluid/Pneumatic Power
• Material Handling
• Metalworking
• Motion Control
• Packaging Equipment & Supplies
• Process Equipment
• Safety
Recognizing industry’s best new productsDEADLINE DECEMBER 7, 2012
YOUR EXPOSURE AND BENEFITS • Special tabloid showcase in the February 2013 issue
• Dedicated online voting website
• Online voting promoted via eNewsleters,
website ads and eBlasts
SHOWCASING OUR WINNERS • Special tabloid showcase in the
April 2013 issue
• The winning products will be
featured in the IW Best Plants
Conference program guide
• Online exposure via website,
eNewsletters and eBlasts
• Social media
• Ability to identify yourself as a leader in
the manufacturing industry
Last year
over 7,000
votes were
casted!
If your products were or will be introduced to the
market between Jan. 1, 2012 and Dec. 1 2012, they
are eligible for this year’s King Awards Competition.
Go to www.NewEquipment.com/KingAwardsEntry
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Electrotherm’s commitment to excellence: Performance, Responsiveness, SupportServing customers worldwide we welcome you to gain from our unparalleled knowledge and expertise.
ELECTROTHERM USA a leader in developing, designing, & manufacturing of:
Electrotherm combines 70 years of experience and core competencies to provide a fast response to industry needs with a high
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For U.S. Sales Contact: Scott Miller 314.412.7546 | St. Louis, MO www.electrotherm-usa.com [email protected] | Terms & Conditions | Privacy Policy
Electrotherm is ISO9001 certifi ed , NADCAP and AMS-2750D compliant. © 2012 Electrotherm Electrical & Metals Products Ltd., All Rights Reserved.
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VIBRO/DYNAMICSvibration & shock control
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888-523-2121
Offering innovative
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Sales Manager
A leading International forging company
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Submit resume to:
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ADVERTISER PAGE
WEB ADDRESS
A. FINKL & SONS Inside Front Cover www.finkl.com
AERODYNE ALLOYS 7 www.aerodynealloys.com
CKS PRECISION MACHINING 31 www.ckstool.com
COR-MET INC. 1 www. cor-met.com
FORGING INDUSTRY ASSN. 25 www.forging.org
GERDAU MACSTEEL Outside Back Cover www.gerdaumacsteel.com
GIRARD ENGINEERING INC 11 www.girardusa.com/ge
INDUCTOHEAT 10 www.inductoheat.com
PRESSTRADE AG 13 www.presstrade.com
SMS - ELOTHERM NORTH AMERICA 16 - 17 www.sms-elotherm.com
SMS - MEER GMBH Inside Back Cover www.sms-meer.us
SUMITOMO HEAVY INDUSTRIES - TECHNO-FORT CO., LTD 9 www.shi.co.jp/stf/english
SUMMIT STEEL CORPORATION 3 www.summitsteel.com
SUPERBOLT INC. 27 www.superbolt.com
VACCARI SPA 15 www.vaccaripress.com
WELD MOLD CO 5 www.weldmold.com
Every effort is made to ensure the accuracy of this index. However, the publisher cannot be held responsible for errors or omissions.
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P I C T U R E T H I S
New Press Hydraulics …
Better Forming Process Control
Siempelkamp is updating the water-
hydraulics for this 100-MN press at Stupino
Metallurgical Co., part of a broader project
involving new electric controls and die heat-
ing technology, and a second hydraulics
package for a closed-die press conversion.
www.sms-meer.com
35,500 t1,320 mm
3
PRESS FORCE
SPINDLE DIAMETER
MONTHS IN OPERATIONAHEAD OF SCHEDULE
More than just on time: In cooperation with the Chinese customer, Wuxi Turbine Blade, the employees from SMS Meer erected the world`s most powerful clutch-operated screw press three months faster than planned. The plant boasts an im-pressive press force of 35,500 tonnes, a spindle diameter of 1,320 mm and except-ional energy effi ciency. Wuxi can now forge signifi cantly more sophisticated parts for its customers from the aircraft and power station industries than has been possible to date.
Quality unites – a fact that our customers and we discover time and again with every new project. Together we develop solutions that give our partners the com-petitive edge in their business. Thanks to this good cooperation, SMS Meer is a leading international company in heavy machinery and plant engineering.
EXHIBITION BEIJING
Beijing 10 – 13 September, 2012China International Exhibition Center New VenueHall W1 Booth J40
Finding your SBQ solution
just got easier!
www.gerdau.com/specialsteel
Quality. Integrity. Reliability. Everything you expect from your
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