Scot Forge discusses hot rolled bar vs cold rolled bar, and forged bar processes to find the right solution for any application. Call today! In the world of bar products, there are different ways to manufacture bars and some different things to consider when purchasing bar. Often lead time, quantity, and quality are what drive decisions when purchasing bar . The end-use application can also play a significant role and can range from a product that utilizes the full length of a 20-foot bar to portions of the bar cut and machined to a unique geometry. In this blog, we discuss the options that can provide both high and low quantity options for buyers - Hot Rolled Bar, Cold Rolled Bar, and Forged Bar. (Please note - There is another process which pushes molten bar through a die called hot-drawing or extruding. This method is not ideal for low quantity purchases.) So, Hot Rolled vs Cold Rolled and Forged Bar Rolling and forging bar boils down to the same fundamental process of reducing the thickness or changing the cross-sectional area of metal by compressive forces. In other words, a large piece of metal known as a billet is pressed down to the size, shape, and length required for a project. This process not only gives the bar shape, but it also adds properties of strength to the bar.  What is Hot Rolled Bar? This is the process of heating a billet to more than 1000 degrees Fahrenheit, above the recrystallizing phase of metal so that it’s workable, then rolling it through a planishing mill or rollers to give it its shape. Heating the metal is vital because changing the molecular structure of the metal form dendrites (thread-like sporadic structures) to grains (organized block-like structures), which only happens when metal is in a malleable state. The creation of stronger metal is not only due to the formation of the grains, but the directional grain flow achieved when the bar is rolled. Pros & Cons Hot Rolled Bar Hot rolled bar is quick and creates single or multiple pieces easily. Unfortunately, where hot rolled bar falls short is with dimensional tolerances. When the metal cools, it contracts and that leads to the likelihood of warping, areas of varied thickness, and a scaled finish, which means machining is required if dimensional precision or finish type is essential. Lastly, with hot rolled bar, timing is everything. If the rolling cycle is missed lead time is drawn out since additional bar wouldn’t be produced until the next mill progression. What is Cold Rolled Bar? This process takes everything we just discussed about Hot Rolled Bar and adds a step. When the bar reaches near-room temperature, it is drawn through dies or rerolled in a progressive rolling process. This additional step inherently adds strain hardening to the bar because it is worked after recrystallization. Strain hardening can only harden the metal so much, the bulk of hardening is achieved during the molecular restructuring provided by hot rolling, depending on the grade.   Pros & Cons Cold Rolled Bar Cold rolled bar has better dimensions, straightness, and increased yield strength. It, again, is used for single or multiple piece requirements. But, with the extra step or rerolling, cold rolled bar is time-consuming and can extend lead times. Unlike a hot rolled bar, however, additional machining for precision isn't required, and the finish is not as scaled. What is Forged Bar? This process, like a hot rolled bar, takes a billet and heats it until it is malleable. This is where the processes differ, rather than rolling the bar to get it to size, forging either hammers or presses the bar to the rough dimensions required. The operation gives the bar a 3:1 reduction ratio minimum, which means that the grain sizes are much smaller and tighter in a forged bar, and it consolidates the centers if there are any piping issues. Then, depending on the diameter of the bar, the bar is put through a planishing mill giving it a smooth, rounded surface.   Pros & Cons Forged Bar Forged bar process takes the best of hot rolled and cold rolled bar and achieves it quickly and efficiently. These bars maintain dimensions and straightness as they cool while having an even higher yield strength because of forgings' unique capability of producing sound-centers during the forging step. The 3:1 minimum reduction helps eliminate any centerline non-consolidation issues that affect bar quality. Unlike the additional step in cold rolling, the extra step of rolling after forging is done while the bar is hot, so there is no time wasted on additional processes after cooling. Forged bar can be used for single or multiple piece requirements and produced on demand. The other significant advantage is for large diameters. The rolled bar is produced to a specific maximum size where the forged bar has a broader span of diameter capabilities.    If you are new to forging or want to compare bar quality, the Scot Forge Bar Team is here to help you navigate your options. Contact our Scot Forge Bar Team for more information about forged bar. Forging may not always be the best option for your project, and if that is the case, we are happy to point you in the direction of vendors we know and trust.

Director of the Office of Trade and Manufacturing Policy in the Trump administration the Secretary of the US Navy, visited North American Forgemasters Steel Forging Complex to inspect the manufacture of shafting and other forgings that form vital components for US Navy vessels. DR. PETER NAVARRO AND NAVY SECRETARY RICHARD SPENCER VISIT NORTH AMERICAN FORGEMASTERS STEEL FORGING COMPLEX, NEW CASTLE, PA. New Castle, PA – October 10, 2019 – Dr. Peter Navarro, Director of the Office of Trade and Manufacturing Policy in the Trump administration, and Richard Spencer, Secretary of the US Navy, visited an area steel mill today to inspect the manufacture of shafting and other forgings that form vital components for US Navy vessels.  They were accompanied by Congressman Mike Kelly, whose congressional district (PA-16) includes New Castle.  Kelly had suggested the visit to the New Castle plant to Navarro and Spencer. They viewed the production of a 72’ foot-long, 190,000 lb. main propulsion shaft for a Virginia Class attack submarine as it was forged—red hot-- under a 10,120-ton capacity forging press at 2,300 degrees Fahrenheit. Other Navy shafts in production in the plant were also on view, including forgings for the Navy’s Arleigh Burke-class destroyer.    The facility is equipped to make large forgings for all of the Navy’s ships and submarines, including aircraft carriers.  Such forgings include also critical parts for the nuclear reactors that supply power to submarines and aircraft carriers.   North American Forgemasters is a joint venture between ELLWOOD, Ellwood City, PA and Scot Forge, Spring Grove, IL.  Executives of those companies were on hand to host the Washington visitors.  David Barensfeld, Chairman of the Board of ELLWOOD, stated: “We are thrilled to receive these important visitors from the Navy and the White House.  Their personal attention to our nation’s industrial supply base is proof of their strong engagement in the successful build-up of our nation’s defense.”    John Cain, Chief Executive of Scot Forge, commented: “North American Forgemasters represents a $100 million dollar investment by Scot and ELLWOOD in the industrial infrastructure necessary for our national defense, on top of the large additional capital investment the two partners have made in their plants to finish parts forged at NAF.  We need for the Navy to require that critical parts such as propulsion shafts be subject to a strict Buy American rule that keeps American shops like NAF familiar, ready and able to make these important parts.” Barensfeld and Cain stressed that North American Forgemasters is also able to make nuclear power supply parts for Navy ships, including parts for their nuclear reactor-fired power, and anticipates receiving orders for these parts from Navy subcontractors.  They stated: “We cordially invite procurement officials from the Navy and its contractors to visit NAF as well as our other plants in western Pennsylvania and Illinois to view other investments our two companies have made to be able to manufacture the Navy parts, and to discuss how we can collaborate on the design and production of critical parts, to better save the Navy time and money in their procurement.”    Under the joint venture agreement, ELLWOOD supplies steel ingots to the joint venture, which forges the parts to a semi-finished shape for further forging and/or machining at the partners’ respective plants in New Castle, Irvine, PA and Spring Grove, IL.   The North American Forgemasters plant is located in New Castle, adjacent to ELLWOOD’s electric arc furnace shop, ELLWOOD Quality Steels, that supplies NAF with its raw material for forging.  Barensfeld stated, “We thank Congressman Kelly for suggesting today’s visit, and for his steadfast support of a strong American defense force, and in particular for his outspoken support for a strong Buy American rule requiring that critical defense parts be made in the United States and not imported from foreign companies.” About ELLWOOD Since our founding in 1910, ELLWOOD has grown organically and via acquisition to become the leading vertically-integrated supplier of quality metals and custom-engineered components for critical applications worldwide. 100% American-owned and made, from raw materials through finished machined and coated products ready for assembly, we provide the products our customers require in the world’s most demanding applications, including those supporting our nation’s defense. While our footprint now spans 30 locations across North America, we haven’t lost sight of what’s right: treating our more than 2,100 team members, industry partners and customers like family. As a family-owned business, we work as a committed partner with our stakeholders to ensure integrity, welcome new ideas, and achieve shared success. About SCOT FORGE Starting as a small hammer shop in Chicago in 1893, Scot Forge is proud to be a 100% employee-owned American manufacturer. Based in Spring Grove, Illinois, U.S.A, Scot Forge is a company with a 126-year track record of success focused on solving our customers’ greatest challenges. With five U.S. facilities and 500 employee-owners, Scot Forge offers the most modern open-die and rolled-ring forging, machining and downstream capabilities in North America. From the wheels of NASA's Curiosity Mars Rover, to mission-critical components for nuclear submarines, to large hydraulic cylinders for the largest mining trucks on the planet, Scot Forge creates the precision forged metal parts used in demanding applications all over the world.

This year, employee-owner Michelle Riedel won Illinois Employee Owner of the Year. We are proud to have Michelle on our team! Every year, each state’s ESOP Association receives nominations from ESOP companies for an individual who goes above and beyond their job description to win the Employee Owner of the Year. This year, a fellow Scot Forge owner nominated Michelle Riedel for Illinois Employee Owner of the Year. From a state that has more than 100 ESOP companies and thousands of employee owners, Scot Forge’s Michelle Riedel was selected as the state’s Employee Owner of the Year! Some of the comments submitted about Michelle spoke about her selfless attitude in helping others – her fellow owners and volunteering in her community. Michelle is one of those people who helps others without seeking recognition. The internal customers she serves can always count on her to get things done on time and better than what is expected. Below are a few quotes from the nomination entry: "Day in and day out I hear and see how her number one priority is not only taking care of our customers but just as important to her is taking care of her fellow employee owners… Michelle is a huge part of organizing our company’s ESOP communications as well as our annual visits to the Washington D.C. Conference. She makes sure our ESOP representatives are scheduled to meet each of our State representatives and have a chance to discuss our ESOP company and the importance of ESOPs to as many representatives as possible… In my opinion the most important program this year that Michelle put together for our employee owners was a “give back to the community” program. She had spoken to local schools where she was told of a need for not just food for the less fortunate but for simple items such as hygiene items for the kids at the schools. Michelle rallied the employee owners and on a volunteer basis had a shopping bag and list of items for these children. Within a few weeks over 150 bags were collected and distributed at the local schools." Michelle – Congratulations on being the Illinois Employee Owner of the Year! We’re proud to have you on our team!

Scot Forge's goal is to exceed customer expectations with every forging we create, starting with a request-for-quote. View our checklist to guarantee your order to your exact needs! At Scot Forge, our goal is to exceed customer expectations with every forging we create. We put our customers' needs first to ensure that every forging is created exactly how you want it, starting when you send a request-for-quote to our technical sales team. Next time you need a quote on a forging, follow this checklist to guarantee your order is made to your exact needs while saving time and money! Click on the image to download and view our checklist.

Scot Forge is proud to provide high-quality solutions to our customers and always exceeding customer expectations! At Scot Forge, our goal is to exceed customer expectations with every conversation we have, order we process and product we forge. We aim to build long lasting relationships with all of our customers to show each of them they are valued and placed in the capable hands of our dedicated employee owners. Scot Forge was presented with a case to select material based on certain properties the customer requested for ram blocks that go into blowout preventers. Blowout preventers are vitally important in controlling wells and preventing another oil spill incident such as the one that occurred in the Gulf of Mexico in 2010. Scot Forge was able to partner with our customer on the metallurgy side of the problem to create a viable solution. Our inside and outside sales teams, along with our forge development team, worked hand in hand with our customer to determine the material needed for this project. The ram blocks Scot Forge produced are shear rams, which are used to cut the drill pipe. The image above to the left shows where the shear rams go within the blowout preventer. The picture above to the right highlights why the ram blocks are so crucial in blowout preventers. The blowout preventer is critical in sealing, controlling and monitoring subsea wells in order to prevent blowouts; making it one of the most critical safety components in the whole operation. To ensure it works properly, every piece of the design must work without fail. Scot Forge takes pride in collaborating with our customers to tackle their challenges. By working together and improving on old methods or materials, we can create an optimal solution.

The team at Scot Forge loves to celebrate by creating a Christmas card to show off our amazing employee owners and spread some holiday cheer! Merry Christmas from Scot Forge It is the most wonderful time of the year! The team at Scot Forge loves to celebrate by creating a holiday card to show off our amazing crew and spread some holiday cheer. The Scot Forge 12 Days of Christmas How We Make Our Card Christmas starts early here at Scot Forge! The holiday season begins back in summer when our Christmas card team first gets together to brainstorm possible themes for our Christmas card video. It isn’t until early fall that the theme is finalized and the real work can begin. The team then writes the script, storyboards the scenes, orders the props and casts employee-owners to be in the video. After that work is done, we book our favorite videography partner! This year we had children of our employee owners voice the lines. Filming begins in November and the video is released mid-December… just in time to spread holiday cheer!

All Ralphie wants for Christmas is a forging so complete... so detailed ... that our customers would be satisfied forever! Click Play Below to Enjoy the Show. We TRIPLE-Dog-Dare You! Oooh fudge! Christmas was on its way. Lovely, glorious, beautiful Christmas. See what Scot Forge has asked for this year from Santa! The Big Man! The Head Honcho! The Connection! Is it a major award? Something fra-gee-lay (must be Italian)? Meatloaf, smeatloaf, double beetloaf? There’s no doubt it’ll be the greatest Christmas gift ever received... Scroll down to see the full Scot Forge cast and crew From all of us at Scot Forge, thanks for watching and Merry Christmas! Share your favorite Scot Forge Christmastime moment and follow us on our social networks. Enjoy the Holidays!

Joining the ranks of other prominent companies such as Honeywell International, Caterpillar Inc., Lockheed Martin, ExxonMobile and Alcoa, Scot Forge becomes the first ever forging company in the United States to receive this honor. EHS Today names Scot Forge as one of America’s Safest Companies in 2014 Since 2002, EHS Today ( Environment, Health, & Safety Today ) has recognized America’s Safest Companies, honoring those whose focus is on developing and maintaining world-class safety cultures. Each year, companies from all types of industries submit applications for review and EHS selects 10-15 standouts to receive this prestigious award. This year, we are proud to announce that Scot Forge Company has claimed one of the 2014 spots. Joining the ranks of other prominent companies such as Honeywell International, Caterpillar Inc., Lockheed Martin, ExxonMobile and Alcoa... Scot Forge becomes the first ever forging company in the United States to receive this honor.   To be considered for the title of America's Safest Company, Scot Forge had to demonstrate “support from management and employee involvement, innovative solutions to safety challenges, injury and illness rates lower than the average for the manufacturing industry, comprehensive training programs, evidence that prevention of incidents is the cornerstone of the safety process, good communication about the value of safety, and a way to substantiate the benefits of the safety process”. (America’s Safest Companies, EHS Today) While this award means a lot to the company, it’s just the beginning. Even though Scot Forge is doing very well by external measures, internally the employee-owners know they can do significantly better. The company’s culture of continuous improvement and commitment to safety means their ultimate goal is zero injuries… and they won’t be satisfied until that goal is sustained. At Scot Forge, everyone is working towards a common goal - to go home at the end of each day without accidents or injuries. By fostering a low-risk work environment, employees stay productive and can focus on other things, like producing quality, precision forged parts. And by taking care of themselves, the employee-owners know they can continue to take better care of their customers. Scot Forge… We’ve Got You Covered! Read the whole SafeStart Success story! Download Now

Forty years ago, the sinking of the Edmund Fitzgerald became the deadliest shipwreck — and greatest mystery — on the Great Lakes. Scot Forge explores the tragedy and the lessons learned about how metals and their applications interact with the harsh, sometimes violent conditions of the open waters. The SS Edmund Fitzgerald underway. Photo by Winston Brown. Forty years ago, the SS Edmund Fitzgerald , the “Pride of the American Flag,” left Superior, Wisconsin at 2:15 p.m. en route to a steel mill on Zug Island near Detroit, Michigan. With a cargo of 26,116 long tons of taconite ore pellets, the ship was the largest vessel of its kind to sail the Great Lakes. Its captain was a 40-year veteran. Twelve hours later, during a severe winter storm with winds of 52 knots and rogue waves up to 35 feet high, the “Mighty Fitz” sank at approximately 7:10 p.m. No distress signal was ever received. All 29 of her crew were lost. Forty years later, the sinking of the Edmund Fitzgerald remains the deadliest shipwreck — and greatest mystery — on the Great Lakes. Speculations and Lessons Learned Tragedies like the sinking of the Fitzgerald teach us a great deal about how metals and their applications interact with the harsh, sometimes violent conditions of the open sea. During WW2, U.S. shipbuilders struggled to understand why the hulls of their mighty Liberty vessels were literally cracking — some splitting in half. The answers were found in both metallurgy and manufacturing. Metallurgists learned that the hull materials in use at the time could not withstand the stresses encountered at sea in very cold climates. Though these waters had been in active use for decades, the change from riveting to welding revealed a fundamental weakness in the hull materials—a transition from tough to brittle at low temperatures. This flaw had previously been countered by the riveted assembly method. When small cracks formed, they were arrested by the rivet holes and did not propagate to any significant degree. When welding replaced riveting, however, no features were available to prevent the crack from spreading. There were nearly 1,500 occurrences, 12 of which resulted in ships breaking completely in half. The realization that metal properties can be temperature-dependent resulted in both new test methods and new alloys to reduce the risk mariners face in cold climate shipping. For the SS Edmund Fitzgerald , the exact cause of the wreck is still undetermined to this day. However, based on clues resting at the bottom of Lake Superior, theories are abundant. One theory speculates that a couple of the Fitzgerald 's giant metal cargo hatches near the center of the vessel had weakened and caved inward from the force of the violent waves, allowing massive amounts of water to swamp the cargo hold, overwhelming its pumps and sinking the ship in a matter of minutes. Although it is was never substantiated, this hatch theory — like the Liberty failures — forced shipbuilders to ask, “How do we make vessels stronger?” One of the potential means of improving a ship’s strength is to incorporate more forged components. Forging, by nature, is stronger and more durable than casting or welding. Thanks to a variety of engineered materials, expanded facilities and new technologies, marine designers now have more options for forged parts than ever before. We asked Pat Nowak, Process Metallurgist for Scot Forge, what the best applications of forging are in marine environments: “For making new ships or repairing existing ones, manufacturers can forge everything from ABS shafts/bars to hollow tubing, piston rings, gears, support bearings and a wide array of custom components.” Same Waters. Better Metals. “Today we work with stronger and lighter metals that have dramatically changed how we approach maritime applications,” Nowak explains. “We have access to new cutting-edge alloys like duplex and super duplex stainless steels, bronze, nickel and aluminum alloys that can better handle corrosive and extreme environments. In fact, many of these forging materials are so strong and corrosion-resistant that we do not even need to paint them to protect them from the elements.” New Super Duplex Alloys A super duplex alloy is the most corrosion-resistant, as measured by Pitting Resistance Equivalent Number (PREN). Super duplex materials have a PREN greater than 40. Bronze Alloys Bronze alloys are extremely popular today for their looks, strength and resistance to corrosion. While they have always been used to make bells, mirrors, weapons and sculptures, they are more prevalent today because the way they are engineered and processed, making them a more attractive option for design engineers. High Yield Strength Materials Today, we also have access to high yield strength (HY) materials that are easier to weld yet ideal for applications that require toughness. They are often used on naval vessels and in other military applications. These alloys come in three grades: HY-80, HY-100 and HY-130, and are designed for low temperatures. Stronger Metals. Smarter Tools. Not only has the quality of engineered metals evolved over the past 40 years, but so have the tools to forge them. Today, world-class manufactures like Scot Forge use 3D computer modeling and forging simulation software to expanded the possibilities what parts can be forged. As a result, today’s marine engineers are able to design vessels that are bigger, lighter, faster, more fuel-efficient and — most important of all — safer for the crews who sail them. Forging a quicker solution to expedite ship repairs and avoid costly dry dock time

There are many benefits to choosing a career in Manufacturing. Check out our info graphic to learn about them. Millions of people work in Manufacturing. There are many benefits to this career field. Scot Forge has put together this infographic to highlight a few of them. Click the image to be directed to the full size image that can be viewed or printed.

Using the advantages of open die forging combined with the near-net shape capability of closed die forging, the forging process can be tailored to optimize time and cost savings. Metalworking and Infrastructure In The U.S. In 2015, North American forging manufacturers supplied $6.2 million in open die and rolled ring forgings for bridges and other Department of Transportation work.1  According to the American Society of Civil Engineers, US bridges are in poor condition, receiving a “C+” grade.2 As a result, the Federal Highway Administration estimates that nearly 25% of the nation’s bridges require repair and replacement as existing structures near the end of their life spans and struggle to handle increasing traffic. Bridges are considered structurally deficient if significant load-carrying elements are found to be in poor or worse condition due to deterioration and/or damage. A “deficient” bridge, when left open to traffic, typically requires significant maintenance and repair to remain in service and eventual rehabilitation or replacement to address deficiencies. The high percentage of deficient bridges and the large existing backlog are, in part, due to the age of the network. One-half of all bridges in the Unites States were built before 1964, while the average age of the nation’s 607,380 bridges is currently 42 years. When bridge owners must select a process and supplier for the production of a critical metal component, they face an enormous array of possible alternatives. Many metalworking processes are available, each offering a unique set of capabilities, costs and advantages. The forging process is ideally suited to many part applications. In fact, forging is often the optimum process, in terms of both part quality and cost, especially for applications that require maximum part strength, custom sizes or critical performance specifications. So why, in the peak of bridge construction (c. 1960), did so many engineers choose castings over forgings? Unfortunately, most Federal bridge safety standards were not created until the late 1960s, in response to the Ohio River bridge collapse. The failure was caused by corrosion and decay of the bridge which weakened it to the point of collapse, killing 46 people. After analysis it was discovered that during the casting process, a microscopic crack formed in a steel eye-bar used in the bridge’s construction, over time stress and corrosion fatigue caused the crack to grow until the component failed. Today, it is well known that castings lack the continuous grain flow, refined grain structure, and directional strength necessary for critical, load bearing operations. The lack of properly oriented grain flow as well as grain refinement can lead to potential part integrity problems causing failures in the field. In the ‘60s, there were hundreds of casting foundries in the U.S. who could supply the complex or large metal components required for bridgework. Castings were cheap and plentiful when compared to steel forgings at that time. As demand for steel castings outpaced supply however, companies began to look outside of the US and Canada for solutions, which ultimately impacted the supply chain in two ways: It gave birth to an off-shore option for steel castings which reached its height and inflict significant damage on the domestic industry in the decades to follow. OEMs were not content back then to wait for the off shore option to fully develop, casting users moved aggressively to invest in a substitute process – steel fabrication. In fact, the presence of fab shops within virtually every manufacturing plant – which we take for granted today – did not exist before the late 1970s and is the direct result of the aforementioned.   At present, the North American steel foundry industry is a shadow of its former self. In 2015, fewer than 200 steel casting plants remain, down from a 1970s high of more than five times that many. Today’s more demanding material users are increasingly obliged by everyday economic and competitive realities to seek a better supply-chain solution and stronger, sounder and technically superior product. However, when it comes to making decisions about the bridge construction and repair, the question still asked is …“casting, fabrication or forging?” The reality that the forging process has come a long way since the 1960s is slowly being recognized. Engineers and metallurgists have increased their education around metal working processes and begun to evaluate the long term benefits of forgings compared to castings or fabrications. Additionally, technological advances have made forgings every bit as competitively priced as alternate methods while providing the means to address the structurally deficient or functionally obsolete challenges faced within the US Infrastructure industry. What is Forging? There are several forging processes available, including impression die (also known as closed die), cold forging, and extrusion. However, here we will discuss in detail the methods, application and comparative benefits of the open die forging processes. We invite you to consider this information when selecting the optimum process for your critical applications. At its most basic level, forging is the process of forming and shaping metals through the use of hammering, pressing or rolling. The process begins with starting stock, usually a cast ingot (or a "cogged" billet which has already been forged from a cast ingot), which is heated to its plastic deformation temperature, then upset or "kneaded" between dies to the desired shape and size. During this hot forging process, the cast, coarse grain structure is broken up and replaced by finer grains. Shrinkage and gas porosity inherent in the cast metal are consolidated through the reduction of the ingot, achieving sound centers and structural integrity. Mechanical properties are therefore improved through reduction of cast structure, voids and segregation. While impression or closed die forging confines the metal in dies, open die forging is distinguished by the fact that the metal is never completely confined or restrained in the dies. Most open die forgings are produced on flat dies. However, round swaging dies, V-dies, mandrels, pins and loose tools are also used depending on the desired part configuration and its size. Open Die Compared To Castings and Fabrications Forging delivers significant economic, manufacturing, and quality advantages when compared to alternative metalworking processes such as directional strength, structural strength, and impact strength. Read more about part integrity and grain flow comparison by visiting our Forging 101: Forging Advantages page. Forging also provides means for aligning the grain flow to best obtain desired directional strengths. It is well known that bridges are prone to cracking and fatigue problems. Therefore, it is helpful to understand how proper orientation of grain flow can ensure maximum fatigue resistance. In open die forging, the metal (once subjected to the compressive stress) will flow in any unconstrained direction. The expanding metal will stretch the existing grains and, if the temperature is within the forging temperature region, will recrystallize and form new strain-free grains. This results in even better resistance to fatigue and stress corrosion than a forging that does not contour the component. This predictable structural integrity inherent to the forging process reduces part inspection requirements, simplifies heat treating and machining, and ensures optimum part performance under field-load conditions. The high-strength properties of the forging process can be used to reduce sectional thickness and overall weight without compromising final part integrity. Additionally, forging can measurably reduce material costs since it requires less starting stock to produce many part shapes. Less machining is therefore needed to finish the part, with the added benefits of shorter lead time and reduced wear and tear on equipment. Virtually all open die forgings are custom-made one at a time, providing the option to purchase one, a dozen or hundreds of parts as needed. In addition, the high costs and long lead times associated with casting molds or closed die tooling and setups are eliminated. Furthermore, by providing weld-free parts produced with cleaner, forging-quality material and yielding improved structural integrity, forging can virtually eliminate rejections (as opposed to fabrications). 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 or geometry can be manufactured relatively quickly and economically. Advances in Open Die Forging Forging suppliers have long used tooling to achieve near net or finish size and shape. Each forging process utilizes forge tooling in different ways to best reduce input material and machining process time. For example, tooling is the cornerstone for impression (aka closed die) forgings. This application is ideal for higher volume repeatable products. The tolerances achieved offer reduced machining needed to obtain finished shapes or sizes. However, over recent years, tooling has allowed the open-die process to become cost competitive when compared to other metalworking alternatives. Although the open die forging process is often associated with larger, simpler-shaped parts such as bars, blanks, rings, hollows or spindles, it can be considered the ultimate option in "custom-designed" metal components. High-strength, long-life parts optimized in terms of both mechanical properties and structural integrity are today produced in sizes that range from a few pounds to hundreds of tons in weight. Many open die manufacturers stock a wide variety of loose tools that can be used to achieve various shapes closer to finish than would be achievable through a pure open die process. Advanced forge shops now offer shapes that were never before thought capable of being produced by the open die forging process. This offering is ideal for prototypes or low volume production where the die block cost for impression die does not provide economic justification. The immediate availability of this tooling can also allow for a shortened production lead time offering flexible order quantities and reduced lead time in situations where needed.

Working in the marine and offshore industries or supplying products for marine applications often requires ABS certification. Learn more about the ABS requirement flow down through the supply chain of a component and how to minimize you risks and costs. Working in the marine and offshore industries or supplying products for marine applications often requires ABS certification. Understanding where in the manufacturing or construction process the certification is required and working with your suppliers can help you minimize costs and production delays while ensuring that your products obtain the certifications needed. WHAT IS ABS? The American Bureau of Shipping (ABS) was chartered in 1862 to certify ship captains. Since then, it has been involved in developing and setting safety and quality standards for ships and offshore structures. ABS standards are recognized globally and are used to ensure that the materials, parts and components, and construction of vessels and marine equipment meet established safety standards. ABS works with the marine industry worldwide as they develop new technologies for constructing marine vessels and offshore structures, revising and updating its certifications to meet the changing industry needs. The Rules and Grades established by ABS for certification are written to provide standards for the design, construction, and periodic survey of marine vessels and offshore structures to promote their safe design and assembly. Materials, parts, and components used in the manufacture of marine vessels and structures must meet the set standards for the vessel or structure in which they will be used. Certifications are specified by the Rules, such as Steel Vessel Rules part 2-3-7/1, or MODU (mobile offshore drilling unit) Rules, or the material grade, such as Grade 2, or Grade 4C. The end use of the component determines the inspections and certifications required, as well as any requirements for inspections during manufacturing: Certain components used in the construction of the vessel or structure must be certified Some of those components must be certified (inspected) as they are being constructed or fabricated to verify that the construction meets ABS standards Some materials must be certified during manufacturing; this will minimize the need for additional certification during construction or fabrication Information about ABS certifications can be found at www.eagle.org . MINIMIZING RISKS AND COSTS ABS certification costs time and money. Certification inspectors are on-site at your facility during manufacturing, construction, or fabrication to verify that your processes meet the standards - and you pay for the time they are on-site. So, it’s important that you understand the Rule requirements for your product to identify the stages in your supply chain where inspection and certification should occur. By doing so, you’ll save your company time and money, and minimize the risk of your products not being certified. Some simple steps can provide you with cost and time savings. Know what the requirements are for your product. Answering a few questions will help: Which ABS Rules or ABS Grade applies to your product? What is the application that your component will be used for? For example, are you manufacturing a component for a jacking system (or the complete system), torque transmitting parts, or a structural component? The application helps determine the section of the Rules or Type Approval Tier that is appropriate for your part. What is the end use of the part? The end use of the part is also used to determine which ABS Rule, Grade or Type Approval Tier is required. For example, if your part is a component in a tailshaft, the process required may be different than if it is being used in rudder stock. Do you have an ABS-approved drawing or Design Approval Document? These drawings or documents show that ABS has approved the design as well as provide an approval number for reference. Partner with your suppliers. It is critical to flow-down your ABS requirements to your suppliers...and your entire supply chain. This is the most important aspect to ensure your component will be accurately certified . It may be required for your suppliers to have inspection performed during the manufacturing process. Clear requirements throughout the supply chain ensure that your component is manufactured under the certification requirements without delays or added costs. Often, by the time the purchase order is submitted to raw material vendors, the ABS Rule requirements are missing. This is caused because the requirements were not flown-down the supply chain. An ideal PO includes information on the all the ABS Rules and Grades or the Design Approval Document from ABS. Your supplier should work with you to ensure that the inspections and certifications are handled at the most effective point in the manufacturing process, eliminating time-consuming errors and reducing inspection costs. It is helpful to have a supplier that is approved by ABS. Using certified suppliers can further minimize the cost and lead-time of inspections (ex: if you need a forging where final heat treatment will take place at another level within the supply chain, and the forging facility is an ABS- Approved supplier, then inspection may not be required at the forge level). With some planning, answering a few questions, and partnering with your suppliers, you can improve the efficiency of your production and reduce the costs of certifying your products for use in the marine industry. THE SCOT FORGE ADVANTAGE At Scot Forge, we are uniquely qualified to provide you with ABS-certified products and materials. We are one of the few U.S. companies that have been audited by the American Bureau of Shipping and APPROVED as a worldwide ABS forging supplier. Our technically trained sales staff has extensive experience manufacturing ABS-certified products and will partner with you to ensure that your part has all the requirements to ensure certification while minimizing time and costs. We are a custom manufacturer of open die forgings and seamless rolled rings, with the capability to forge parts up to 100,000 lbs. and roll rings up to 252” in diameter. From gear box repair to broken rudder stock, contact us at today see how we can help you with your marine part and get you out of dry dock and back in commission. Click here to download the Working with ABS Certifications PDF. Joe's Story: Forging a quicker solution to expedite ship repairs and avoid costly dry dock time