Die Forging
Why Choose Us
Expertise
Our knowledge and expertise ensure the production of fixtures that meet or exceed industry standards.
Precision
Philloy's casting process ensures dimensional accuracy and consistency, resulting in fixtures that precisely meet the design specifications.
Customization
Whether it's modifying existing designs or creating entirely new fixtures, we can accommodate various specifications and preferences.
Quality Assurance
Philloy implements rigorous quality control measures throughout the casting process to ensure the highest quality standards are met.
The forging process refines the grain flow of stainless steel, which enhances the alloy's capabilities. View the key capabilities of forged stainless steel below. High corrosion resistance makes stainless steel forgings ideal as components in pumps and marine, chemical, and petrochemical equipment.
Stainless steel forged fittings are essential components of some industrial or commercial systems, making the joining of two or more pipes, possible. Piping systems less than 2 or 4 inches in diameter generally use forged fittings and differ from buttweld fittings used for piping systems with larger diameters.
The manufacturing process of stainless steel forged fittings involves the application of thermal and mechanical energy to shape solid stainless steel blanks into functional shapes within the tolerances established by the applicable specifications. These forged fittings are available in a wide range of sizes and diameters, and there are several shapes of forged fittings to cater to any type of pipe joint.
Forged steel fittings have to meet several requirements to ensure optimal functionality as socket weld or threaded fittings.
These steel forged fittings have to be corrosion-resistant. If a socket weld or threaded steel forged fitting is susceptible to rust, premature deterioration and leaks can result. Corrosion can also make it difficult to install or remove a threaded steel forged fitting.
Stainless steel forged fittings should also be lightweight, but durable and abrasion-resistant during high-temperature services or strenuous weather conditions. Additionally, stainless steel forged fittings should be suitable for installing high-pressure (3,000lb, 6,000lb, and 9,000lb) piping systems.
Each fitting has a class grading of 3000, 6000, or 9000, representing the maximum pressure that the stainless steel forged fitting can withstand. Pipes in schedule 80/XS require class 3000 fittings, pipes in schedule 160 require class 6000 fittings, and XXS pipes with thicker walls require class 9000 fittings.
Stainless steel grades that generally meet these requirements are in the 300 series, including, among others, 304, 304L, 309, 310, 316, 316L, 317L, 321, and 347. The L-grades offer additional corrosion resistance after welding. Some socket weld steel forged fittings are 304L stainless steel.
The Basic Process Of Stainless Steel Forging Stamping
'lt is awesome to work with Creative. amazingy organized,easy to communicate with. responsive with next iterations,and beautiful work.
Cutting
It is a process of separating the sheet material along the unclosed contour, and its purpose is to cut a large area of sheet material into strips or small sheets suitable for punching. This work is usually carried out on a shearing machine.
Blanking
Punching and blanking are collectively referred to as the blanking process, and they are both processes that separate the sheet material along a closed contour. The operating methods of punching and blanking are the same, but they have different functions. Blanking is the use of a die to punch a piece of metal from the blank as a finished product or a blank for next processing.
Deep drawing
It is the process of making flat blanks into hollow parts, also known as drawing.
Bending
The process of turning a part of the stainless steel forging blank at a certain angle relative to the other part. The edges of the convex and concave molds of the bending mold must have certain rounded corners.
What are the characteristics of stainless steel forging process？
Poor thermal conductivity. Stainless steel contains a lot of alloy elements such as chromium, nickel, manganese and titanium, so its thermal conductivity is poor. The more alloying elements, the worse the thermal conductivity. Below 800 ℃, its thermal conductivity is about 20% lower than that of ordinary carbon steel and alloy steel? The thermal conductivity of 50% at high temperature is similar to that of magnetic steel and alloy steel. Strictly control the heating temperature and heating speed during heating.
Low plasticity. The plasticity of stainless steel decreases with the increase of temperature, especially with the increase of martensite temperature. The heating shall be uniform to avoid cracking due to uneven deformation. When forging this kind of steel, its deformation degree shall be less than 60%, and the tools used must also be preheated to 200 ~ 250 ℃. When forging stainless steel ingot, it shall be lightly and quickly forged first, and then hammered through gradually, and the surface cracks shall be removed in time.
Large deformation resistance. Stainless steel has great deformation resistance at high temperature. Therefore, large tonnage equipment and wear-resistant die materials need to be used when forging stainless steel. The high temperature resistance of stainless steel is between nickel base superalloy and general alloy structural steel, and increases with the increase of deformation degree, so too much deformation degree can not be adopted.
The recrystallization temperature is high. Therefore, the forging temperature range of stainless steel forgings is very narrow, which is prone to overheating and overburning. Therefore, the forging temperature range should be strictly controlled. The forging temperature range of stainless steel is only about 250 ℃, and some are slightly wider.
Large size shrinkage. The main reason is that the linear expansion coefficient of austenitic steel is large. Therefore, when the forging is finally formed, the size of the forging should be controlled according to the large shrinkage rate to avoid scrapping due to insufficient size after cooling.
A Guide to Stainless Steel Forgings
There are several grades of stainless steel alloys, each offering different properties ideal for unique applications. The most common stainless steel series of grades are the austenitic 300 series and the martensitic 400 series. The 300 and 400 series of stainless steel grades have key differences in chemical composition, properties, and applications:
Chemical Composition
The 300 series of stainless steel grades are austenitic, meaning they have a face-centered cubic crystal structure. They are composed of chromium (18-20%) and nickel (8-10%). They also contain small amounts of carbon, manganese, phosphorus, sulfur, silicon, and nitrogen. In contrast, the 400 series of stainless steel grades are martensitic or ferritic, which means they have a body-centered cubic or face-centered cubic crystal structure. They mainly comprise chromium (11-27%) and little or no nickel. They also contain small amounts of carbon, manganese, phosphorus, sulfur, silicon, and sometimes molybdenum.
Properties
The 300 series of stainless steel grades are known for their excellent corrosion resistance, high ductility, and low yield strength. They are also non-magnetic, have good weldability, and are easily formable. The 400 series of stainless steel grades have lower corrosion resistance, higher yield strength, and are magnetic. They are also harder and more brittle, making them more difficult to form and weld than the 300 series.
Applications
The 300 series of stainless steel grades are commonly used in applications that require high corrosion resistance, including the food and beverage and medical industries. They are also used in commercial and consumer kitchen appliances, utensils, and equipment. In contrast, the 400 series of stainless steel grades are commonly used in applications that require high strength and wear resistance, including the automotive and aerospace industries.
How To Forge Stainless Steel Forgings?
The precision of rough or stainless steel forgings is higher. The application of advanced technology and equipment can achieve little or no cutting.
The metal materials used in forging should have good plasticity, so that under the action of external force, plastic deformation can be produced without rupture. Among the commonly used metal materials, cast iron is brittle material with poor plasticity and can not be used for forging. Copper, aluminum and their alloys in steel and non-ferrous metals can be machined under pressure in cold or hot states.
Improve the internal structure and mechanical properties of stainless steel forgings. Stainless steel forging blank after forging processing, its organization, the performance is improved and improve, forging processing can remove the inside of the metal ingot casting defects such as blow hole, shrinkage cavity and dendritic crystal, and as a result of the metal plastic deformation and recrystallization, can make the rough grain refinement, get the dense metal organization, so as to improve the mechanical properties of stainless steel forgings. In the design of parts, if the force direction and fiber organization direction of parts are selected correctly, the impact resistance of parts can be improved.
High utilization rate of materials. Metal plastic forming mainly depends on the relative position of the metal body tissue rearrangement, without the need to cut the metal.
Higher productivity. Forging processing is generally the use of press and forging hammer for forming processing.
It is not suitable for stainless steel forgings with complex shape. Forging is formed in the solid state, compared with casting, metal flow is limited, generally need to take heating and other technological measures to achieve. It is difficult to manufacture the parts or blank with complex shape, especially the parts with complex inner cavity.
So bear the impact or alternating stress of the important parts (such as transmission spindle, gear ring, connecting rod, rail wheel, etc.), should be made of stainless steel forgings blank processing, so forging processing in machinery manufacturing, mining, light industry, heavy industry and other industries have been widely used. Forging is one of the main methods for the production of blank and parts in machinery manufacturing. It is often divided into free forging and die forging.
Alloy Steel Forgings. Forged alloy steel is a robust and versatile metal that provides a reliable, cost-effective material option for a wide range of industrial applications. Parts manufactured from forged alloy steel contain unique properties not found in standard carbon steel.
1. High strength, good plasticity and toughness. Due to the effect of alloying elements, its strength is 25% - 50% higher than that of carbon steel forging, its elongation is 15% - 23%, and its impact toughness at room temperature is higher than 60j.
2. Good weldability. Because of the low carbon content, low alloy element content, good plasticity and low hardenability, not easy to have cracks after Heat treatment(Quench&temper)
3. Cold and hot pressure processing performance is good. Because of its good plasticity and small deformation resistance, during the forging manufacturing process it is not easy to produce cracks after pressure processing
4. Good corrosion resistance. It has higher corrosion resistance under various atmospheric conditions
5. Durable. This type of steel has a very high tensile strength and can withstand temperatures ranging from -50 to +300 degrees Celsius. It also has a high corrosion resistance, which makes it perfect for use in industries that involve chemicals and an aggressive environment.
6. Strong yet flexible. Alloy steel forging is stronger than carbon steel and can be bent or twisted into different shapes without breaking.
7. Resistant to heat. Making it ideal for use in industries like power generation and aircraft manufacturing. It doesn't lose its shape when exposed to high temperatures.
Application of Alloy Steel Forging
Forged alloy steel blanks are with various special properties such as high strength, high toughness, wear resistance, corrosion resistance, low temperature resistance, high temperature resistance, and non-magnetism. They have a wide range of applications, mainly including the following aspects:
Automobile making
Alloy steel forging is used to manufacture engine blocks, crankshafts, pistons, and various components of automobiles.
Machinery manufacturing
Alloy steel forging is used to manufacture gears, gear shafts, connecting rods and worm gears, etc.
Shipbuilding
Alloy steel forging is used to manufacture ship main shafts, large gears, sprockets, pistons, tubes etc.
Petrochemical industry
Alloy steel forging is used to manufacture various valves, fittings, and containers, which can improve the reliability and service life of equipment.
Certifications
Our Factory
Philloy Machinery has a strong technical team, a total of 5 engineers, each engineer has at least 20 years of work experience in the field of casting, forging and machining. When receiving customer's request, we can recommend the most efficient manufacturing process for our customers and offer professional suggestions on product design. Reinforced by advanced inspection Equipment and strict QC process, we can confidently compensate our customers for any quality issues of our product. Besides, with our warehousing service and global presence, we are ensuring our customers on-time delivery and customer service so they will have their components whenever they need.
