March/April 2018 forgingmagazine.

com

THE FUTURE OF
AUTOMOTIVE
STEEL
Bar steel products — including
forgings — remain critical to
successful automotive design
and production. And there are
opportunities for forgers to shape INSIDE:
that future. p.18
EXPANDING, FLEXING
HEATING PROCESSES
p.19
NEW MULTI-DIRECTIONAL
PRESS AT ECG p.21
THE VISION OF THE
BLACKSMITH p.28
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Forging the
Future

Finkl Steel has been THE NAME in high Chicago 800-DIE-BLOCK

quality die steels for over 100 years. Three Composite 800-521-0420
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12500 Grand River Road, sales@cor-met.com
Brighton, MI 48116
800-848-2719 www.cor-met.com
“Ask for a weld shop tune up”
CONTENTS
F E A T U R E S
MARCH/APRIL 2018
VOL. 28, NO.2

MATERIALS
19
16 Meeting the Automotive
Sector’s Future Needs
Bar steel products, including forgings,
remain critical to successful automotive
design and production. And there
are opportunities for enhancing that
success.

PROCESSES
19 Expanding and Flexing
Heating Processes
TimkenSteel’s new AQTF adds capacity and
functionality to the task of heating quality steel long
products ON TH E C OVE R:
Design by Bill Szilagyi, graphics
SUCCESS STORY editor. Photo by courtesy of SMS
24 21 New Multi-Directional Press at ECG group.
Ellwood Crankshaft Group is now able to forge
crankshafts up to 14 m long and weighing up to
50 mt. ARTICLE REPRINTS and E-PRINTS:
Increase exposure by including
SAFETY article re-prints and e-prints in your
22 Five Trends to Watch next promotional project. High-
quality re-prints and e-prints are
in Machine Safeguarding available by contacting: Reprints,
Manufacturing equipment builders are ePrints & Content Reuse, Nick
important contributors to the development and Iademarcol, Wrights Media,
implementation of safety standards, including 877-652-5295; reprints@informa
reprints.com; Microfilm copies,
setting new strategic objectives.
PRO-QUEST: 800-521-0600

DEPARTMENTS
Editor’s Note ..........................................4
Industry News ........................................6
28 FIA/FIERF News ..................................... 14
Meetings/Calendar ................................ 14
Newsmakers......................................... 15
New Products ....................................... 24
Business Staff ....................................... 26
Advertiser Index ................................... 27
Product Express.................................... 27
Picture This .......................................... 28

FORGING (ISSN 1054-1756) is published in January/February, March/April, May/June, July/August, September/

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 since 1863

Best quality is our ultimate ambition

Our nearly comprehensive range of traditional machine tools for forming technology
comprises hydraulic presses, die forging hammers, counterblow hammers as well as
screw presses, pre-forming units, forging and cross wedge rolls, and automation of
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LASCO machines and lines for

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 EDITOR’S NOTE

How Will the Market React? EDITORIAL STAFF

T
wenty years ago, when Microsoft Corp. founder Bill Gates deigned to appear before a Con-
gressional panel to address the then-plausible accusations that the computing and software EDITOR
enterprise he headed then was operating as a dangerous monopoly, the moment was consid- Robert E. Brooks
ered a historic match-up of power versus justice, opportunity versus principle, the future versus the Robert.Brooks@informa.com
past. It was also one of those odd moments when the people we assume are responsibly managing
GRAPHICS EDITOR
important ideas and duties — government officials, heads of businesses, purveyors of information
Bill Szilagyi
— are really just small people in big jobs, as credulous or irresponsible, or self-serving, as the peo-
Bill.Szilagyi@informa.com
ple we encounter and endure every day.
Today, the world is more chaotic and unpredictable, in my view due to the steady decline of cred-
ibility and responsibility by and for public institutions (government, businesses, schools, etc.); and CONTENT DIRECTOR —
due to the low-regard most of us now hold for individuals, especially those in positions of authority. DESIGN &
So, when Facebook founder Mark Zuckerberg appeared to testify in Congress this month, the MANUFACTURING GROUP
images were familiar – but the effect was more amusing than intriguing. The reason is that no one Karen Field
can long sustain the necessary composure to learn the meaning of some development, or to listen Karen.Field@informa.com
to the intentions of other people try-
WE DON’T GIVE ANY RESPECT TO THINGS THAT ing to explain a point or a concern.
CANNOT AMUSE AND ENGAGE US. WE ARE THE We don’t need to learn anything new
FOCUS OF ALL OUR ATTENTION. now. We’re all too clever, too in-the-
EDITORIAL-
ADVISORY BOARD
know, too ready to let loose with a
wisecrack that will get all our listeners focused on us. We don’t give any respect to things that cannot
amuse and engage us. We are the focus of all our attention. Alvin M. Sabrof
This is a pity, because Zuckerberg’s appearance may have significance, now and in the future. Metalworking
The role of Facebook would not seem as relevant today as Microsoft did in 1998. While Microsoft Consultant Group
then was the primary supplier of computer hardware and business software, to businesses, to public
and private institutions, and to individuals, Facebook is a service used mainly by individuals for Dr. Rajiv Shivpuri
diversion and personal communication. Microsoft drew billions of dollars in revenue for its products The Ohio State University
at that time; “… we run ads,” Zuckerberg told one of his questioners trying to unlock Facebook’s
devious plots.
The most significant difference between 1998 Microsoft and 2018 Facebook is not the products
they offer but the market in which they do their respective businesses. The former offered specific
items for sale; the latter constantly evaluates the activities happening on its platform and finds ways
to tag it for sale, and resale. The users of Microsoft came and went, and if Microsoft performed well
they came again. The users of Facebook arrive, and stay, and become the product that Facebook can 1100 Superior Ave.
offer — to advertisers, of course, but also to buyers of data seeking their own new audiences to mine Cleveland, OH
for revenue. 44114-2521
And most of those users care not at all if their information is collected and repurposed. They only Tel. 216-696-7000
want to be amused or entertained. Fax 216-696-7932
Facebook’s way of doing business is not new, but its market share is unprecedented. It has access
to subscribers/products in places that its would-be regulators cannot reach. It is global in a way that
most of us have never comprehended “global” in describing any other business — and so the wholly
separate controversies in which government regulators seek to impose “fairness” in markets like
steel or aluminum are comparatively insignificant.
The market for products has become small and transitory. The market for information, for data,
www.forgingmagazine.com
for intellectual property, has become vast and in some ways permanent. The information Facebook
or another entity collects on us may last longer than we are alive — and so the next time some high-
tech mogul appears before regulators, be prepared not to laugh too obviously.
ROBERT E. BROOKS I EDITOR

4 I FORGING I MARCH/APRIL 2018

 A LEGACY OF INNOVATION,
CONTINUOUS IMPROVEMENT

2017 ASM Historical Landmark

Award for Floodwelding Innovation

2017

Christina Miller
Weld Mold, VP COO

AND ACCOMPLISHMENT
Matt Kiilunen founded Weld Mold in 1945, growing our company through Call: 810-229-9521
floodwelding innovation, an accomplishment that has taken forge die www.weldmold.com
repair to the next level–increasing forging die life while reducing customer
costs. Since then, continuous improvement has added to our legacy:
• By developing specially designed machinery that would facilitate and
improve the floodwelding process even more.
• By introducing RC-17™ technology in 2017, enabling floodwelding
to be totally remote-controlled for better operator health and safety.
• And by developing over 3,000 performance-matched high-quality
custom solutions for welding and forge welding, providing customers
more options than ever to improve weld quality and save money.
In 2017, ASM International recognized Weld Mold for floodwelding
innovation with its prestigious Historical Landmarks Award, designating
sites and events that have played a prominent role in the growth and develop-
ment of metals and metalworking. In November, our own Christina Miller was
recognized as a 2017 Woman of Excellence in Metalforming & Fabricating.
Contact us today. Find out what Weld Mold innovation, continuous
improvement and accomplishment can mean to your company. ISO 9001 Certified
FORGING NEWS
…READ MORE detailed reporting on forging operations and technology at forgingmagazine.com/news
Isothermal forging is a closed-die process in which dies
and workpieces are heated to the same temperature. ATI
has three such presses installed at Cudahy, WI.
ATI Investing $95M
in Isothermal Forging
A llegheny Technologies Inc. directors
approved a $95-million capital invest-
ment project to expand the isothermal forg-
ing and heat-treating capacities in Cudahy,
WI, to address growing demand from the
aerospace jet engine market. The three-
year project will establish ATI’s fourth iso-
thermal press at that location, which ATI
acquired in 2011 as part of its takeover of
Ladish Co. Inc.
In addition to forging carbon and al-
loy steel, superalloys, titanium, and other
specialty materials, ATI manufactures
castings, mill products, and machined
components. Its specialty alloy products
include titanium, nickel and cobalt alloys,
stainless steels, and superalloys, as well as
nickel-based alloy and titanium-based alloy
powders.
The Wisconsin plant, known now as ATI
Forged Products, has about 700 employees
and the new capacity will result in up to 125
more workers, according to local reports.
The Wisconsin Economic Develop-
ment Corp. approved a $7-million enter-
prise-zone tax credit over seven years for
the project. The specific amount of tax cred-
its ATI will receive depends on job-creation
and –retention targets, and the amount of
capital invested.
Isothermal forging is a closed-die pro-
6 I FORGING I MARCH/APRIL 2018
cess in which the dies and the workpieces
are heated to the same temperature, so that
forming can take place without loss of tem-
perature in the workpiece. It’s a preferred
process for forming engineered parts, in-
cluding jet-engine and other aerospace
components in high-density lightweight
alloys.
Last year, ATI entered into a long-term
agreement to supply isothermal forgings
to Pratt & Whitney, a manufacturer of jet
engines for commercial and defense aircraft
programs. Pratt & Whitney is expanding
its own isothermal forging capabilities for
turbine disks and compressor rotors, at its
engine manufacturing complex in Colum-
bus, GA.
ATI has not indicated the design or ca-
pabilities of the new isothermal forging
press and heat-treating installation. Ladish
installed the three isothermal presses cur-
rently in place at the Wisconsin plant. One is
rated for 4,500 tons and another for 10,000
tons of forming capability. The third, rated
at 12,500 tons, was installed in 2007-8 and
described at the time as the world’s largest
of its kind.
“We continue to invest in our advanced
forging capabilities in support of our aero-
space customer’s ramp-up of next genera-
tion jet engine production. Once completed
and fully qualified, this critical growth proj-
ect will enable us to meet the increasing
production requirements for existing long-
term agreements with our engine OEM
partners,” stated Rich Harshman, chair-
man, president and CEO.
…READ MORE
Shareholders
Accept Melrose;
Dana Loses GKN
Powertrain
M elrose Industries, the “turnaround
specialist” that launched an un-
friendly takeover of GKN plc in Janu-
ary, won its bid with the endorsement of
52.4% of voting shareholders accepting
the $11-billion cash-and-stock offer. The
victory ends the effort by GKN to pre-
serve its independence and sell-off its
Powertrain division to Dana Inc.
If that deal had been completed, it
would have expanded the Dana driveline
product range and its automotive market
share, while GKN would have become
a more “pure play” aerospace business.
A new GKN management team, in-
stalled in January, also put the group’s
powder-metallurgy business up for sale
in the first wave of a restructuring pro-
gram aimed at improving its revenues
and financial performance. It indicated
other business lines would be considered
for sale too, including GKN Driveline’s
Wheels, Cylinder Liners and Off-High-
way Powertrain businesses. It said it
planned to continue developing its GKN
Aero Additive Manufacturing, Driveline
China, and eDrive Systems business.
Now, the GKN board of directors has
recommended that shareholders accept
the Melrose offer, though it restated its
view that the offer “fundamentally un-
dervalues” the GKN shares. That recom-
mendation, it noted, was meant to allow
shareholders to gain some value for their
Every SBQ purchase from Gerdau
includes a personal commitment.

“We improved our

capabilities and
increased capacity
with an intense focus
on our customers’
long term success.”
Mark Marcucci
–President
Gerdau Special Steel
North America

Just as you invest in your business to keep up with the evolving

needs of your customers, you should expect the same from
your supplier. Gerdau continuously invests in its facilities
and people by utilizing the most technically advanced
equipment, processes and management systems to ensure
we will meet your needs now and in the future. This is why www.gerdau.com/northamerica
Gerdau steel is the strength behind your brand.
INDUSTRY NEWS
GKN plc is an important player in global aerospace manufacturing, contributing components,
systems and technologies for aerostructures, aircraft engines, and aftermarket and MRO
services.
holding before Melrose declares its offer
unconditional, as it has indicated it will
do once it gains 75% of voting shares.
“We are, of course, disappointed by
today’s outcome and continue to believe
Dana would be the best owner and op-
erator of GKN Driveline,” stated Dana
president and CEO James Kamsickas.
“This has always been an opportunity,
not a required or critical asset. Dana is
a strong, thriving company, and we will
continue our focus on the execution of
our enterprise strategy, delivering for
customers and remaining responsible
stewards of our shareholders’ capital.”
In Britain, the Melrose approach to
GKN had been regarded with caution
by politicians, because of the prestige of
GKN’s engineering and manufacturing
capabilities, and because of Melrose’s
reputation for breaking up and selling
off businesses. GKN’s 6,000 British em-
ployees and their long-term financial se-
curity has been a parallel concern.
Melrose in turn has pledged to invest
in R&D programs, and that the acquired
GKN would remain headquartered in
Britain.
“We are delighted and grateful to have
received support from GKN sharehold-
ers for our plan to create a U.K. industrial
powerhouse with a market capitalization
of over £10 billion (est. $14 billion) and a
tremendous future,” stated Christopher
Miller, Melrose’s chairman.
…READ MORE
Bodycote in LTA
with Safran
B odycote plc entered into a long-term
agreement to supply manufactur-
ing services to aerospace manufactur-

Bodycote has 180 operations in 23 countries offering commercial heat-treating and specialty thermal
processing services.
ing group Safran, including thermal
spray coatings, electron-beam welding,
hot-isostatic pressing, and heat treat-
ment. Safran, headquartered in Paris,
manufactures aircraft and rocket en-
gines and aerospace components.
The duration and other terms of the
agreement were not announced.
Bodycote has 180 oper at ions i n
23 cou nt r ies of fe r i ng com me rcial
heat-treating and specialty thermal pro-
cessing services. Its goal is to prolong
the working life of critical components
and provide in-service protection from
factors such as abrasion, temperature,
and wear.
The Safran agreement will support
the expansion of that group’s civil aero-
space programs, including CFM LEAP
jet aircraft engines, Safran Helicopter
Engines, and Safran Landing Systems
(landing gear systems.)
Bodycote noted its services for Safran
initially will be provided from its loca-
tions in France and Belgium.
Recently, Bodycote announced plans
to install a new “Mega-HIP” hot-iso-
static pressing system at its operation
in Sint Niklaas, Belgium, suitable for
high-pressure, high-temperature pro-
cessing of Nadcap-certified aerospace
components, in line with rising Euro-
pean demand in that sector.
Hot-isostatic pressing (HIP) com-
bines high-temperatures and inert-gas
INDUSTRY NEWS
(e.g., argon) atmospheres under very
high pressure (up to 30,000 psi) to den-
sify workpieces and/or to bond dissimi-
lar materials.
Heat treating is a controlled process
for altering the microstructure of materi-
als, such as metals and alloys.
Thermal spray coatings are among
Bodycote’s portfolio of surfacing tech-
nologies for prolonging the working life
of components and protecting them from
environmental factors, such as corrosion
and abrasion.
Electron beam welding is a specialty
metal joining technique used to create
high-integrity joints, with minimal dis-
tortion. …READ MORE
Carpenter
Buys Metal 3DP
Manufacturing Biz
C ar penter Technology Cor p. pur-
chased MB CalRAM LLC, a pro-
ducer of metal parts using powder-bed
fusion additive manufacturing. The pro-
ducer and distributor of specialty steels
and alloy materials, did not announce the
cost of the acquisition nor other details of
its purchase.
CalRAM maintains a 25,000-sq.ft.
operation in Camarillo, CA. Its produc-
tion systems are described as Arcam
A2X and SLM 280 electron beam melt-
ing (EBM) equipment, which it uses to
Powder-bed fusion uses a laser or an electron beam to melt and fuse layers of metal powders to create
functional parts according to CAD patterns.
10 I FORGING I MARCH/APRIL 2018
produce prototypes and low-volume pro-
duction components.
“This strategic acquisition builds
upon our existing additive-manufactur-
ing capabilities and provides direct entry
into the rapidly expanding part produc-
tion segment of the additive manufac-
turing value chain,” stated Tony Thene,
Carpenter’s president and CEO.
Last spring, Carpenter established
partnership with metal processor/dis-
tributor Samuel, Son & Co. to provide
supply-chain services for AM producers
and customers. Separately, Carpenter
established a supply relationship with
Desktop Metal, Inc. to provide more than
20 CarTech ® alloy grades in premium
materials cartridges for use in Desktop
Metal’s metal 3D printing systems.
“Powder bed fusion” refers to various
technologies often described as metal
additive manufacturing or metal 3D
printing, including direct metal laser sin-
tering (DMLS), electron beam melting
(EBM), selective heat sintering (SHS),
selective laser melting (SLM), and se-
lective laser sintering (SLS). It involves
a laser or electron beam melting pow-
dered metals or alloys according to a pat-
tern determined by STL programming,
derived from CAD. The designs are
realized in a structural fashion, fusing
successive layers of material by melting
powder into metal.
“The addition of CalR AM brings
industry-leading technology and pro-
cesses coupled with a talented team, and
is a strong complement to Carpenter’s
deep technical experience in producing
highly engineered metal powders and
wire for additive manufacturing appli-
cations, including mission-critical appli-
cations such as jet-engine fuel nozzles,
rocket-thrust chambers, and orthopedic
implants” Thene added.
“As additive manufacturing continues
to evolve into more advanced compo-
nents with increasing complexity, our
customers are seeking partners who can
not only produce parts, but also possess
metallurgical expertise to help deter-
mine the best materials and processes
to fit their needs in demanding applica-
tions,” according to Thene.
…READ MORE
É READ MORE is your tip to
visit forgingmagzine.com/
for up-to-date, extensive,
informative reporting on news
and developments for forging
operations, including:
¥ ATI Investing $95M in
Isothermal Forging
¥ Shareholders Accept
Melrose, Dana Loses GKN
Powertrain
¥ Bodycote in LTA with Safran
¥ Mettis Aerospace Building
New CBH Press
¥ Carpenter Buys Metal 3DP
Manufacturing Biz
¥ Park-Ohio Acquires Canton
Drop Forge
¥ Linamar Expanding Forging
Capabilities in N. Carolina
¥ AAM, Drexler Expanding
Programs for Automotive
Market
¥ New Wheel Finishing Center
for Otto Fuchs
¥ Bodycote Expanding HIP for
EU Aerospace Sector
¥ SMS Developing High-
Throughput Furnace
¥ ThyssenKrupp Reorganizes
Forging Business Line
¥ FOMAS Partnering to
Produce Powder Metals
¥ Arconic, Airbus Link to
Expand 3DP for Aerospace
 cludes more than 60 forging units of up
to 12,000 mt.
“There’s always a great sense of
anticipation at Mettis every time new
technology arrives on site,” according
to CEO Gordon Fraser. “Recently, we’ve
invested heavily in our state-of-the art
machining division and laboratory, in
particular, and now it’s great to be taking
delivery of the first new press in over 30
years, as part of our significant growth
plans.”
Foundation work is in progress at the
Redditch plant, an integrated operation.
The new press is expected to be in pro-
duction by summer. …READ MORE

The 40-mt counter-blow hammer press

designed by Bêché and now being installed
by Mettis Aerospace at its plant in Redditch,
England.

Mettis Aerospace
Building New
CBH Press
M ettis Aerospace, a designer and
manufacturer of precision forged
and machined aerospace components,
launched construction of a new, 40-mt
counter-blow hammer press at its plant
in Redditch, England. The project is an-
ticipated as one of the largest forging
presses in the U.K., and described by
Mettis as its largest capital investment
in several decades, and will allow the
producer to manufacture specialty alloy
forgings weighing up to 750 kg.
This Bêché press, called the DG40,
will be able to forge components up
to 1.80x0.65 m, enhancing the plant’s
current forging capabilities, which in-

FORGINGMAGAZINE.COM I FORGING I 11
INDUSTRY NEWS

High-Pressure
Fluid Cell Press for The Quintus fluid cell
press for forming
Aerospace Parts parts with complex
geometries in hard-to-

T restad Laser AB, a subcontractor form materials.

for formed metal components to

GKN Aerospace and Siemens Industrial
Turbomachinery, among others, ordered
a new Quintus Technologies high-pres-
sure fluid cell press for its operation in
Trollhättan, Sweden. The investment is
part of Trestad’s strategy to expand its
metal-forming capabilities, in line with
its laser cutting, welding, machining, and
milling operations.
“We started out with welding and shap-
ing, and the business has been focused on
laser for years, but our assessment is that
demand for shaped details will increase,”
explained Per Andersson, who runs the the international standard which the avi- is that the certification will have several
business together with his three brothers. ation industry requires from its subcon- positive side effects in other areas of our
“That is why we have chosen to invest in tractors,” he continued. “Our assessment business.” …READ MORE
modern, high-pressure equipment from
Quintus. Our customers often demand
complex and unique components made FORGING NEWSBRIEFS
of materials that are hard to form, in rela-
Editors’ note: The Gerdau steelmaking operation in Monroe, MI, will convert from
tively short series, and with high demand
producing 210 mm to 240 mm square blooms. The transition, which will be efective
for short delivery times. The Quintus in September this year, is part of a Gerdau initiative to enhance steel cleanliness in line
technology is well suited to meet those with the changing standards for critical automotive market products, as well as the
requirements.” standards in other manufacturing markets. An earlier report was insuficiently clear
The QFM 1.1-800 Quintus fluid cell on these details. We regret any readers’ confusion.
press applies 8,000 mt of pressure over
a forming area of 1,100 mm (43 inches). SIFCO Industries Inc. in Cleveland is the first U.S. forging manufacturer to obtain
The press will be put into operation in Nadcap Metallic Materials Manufacturing certification. The audit undertaken for this
early summer. The Quintus process re- certification included forging equipment and processes to ensure manufacturing
quires only one rigid tool half; the other consistency. Other processes audited were billet cutting, preparation, and heating, as
well as post-forging operations. SIFCO previously achieved NADCAP certifications in
tool half is replaced by a flexible rubber
heat treating, chemical processing, and non-destructive testing.
diaphragm under uniform hydrostatic
pressure. This design reduces tooling Hatebur Metalforming Equipment Ltd. integrated the Hatebur Swiss Precision AG
costs and reduces the time needed for tool assembly plant, which had been operating as an independent subsidiary: “In practice,
production. nothing about the relationships will change,” emphasized CEO Thomas Christofel.
“The decision to invest in a Quintus The assembly plant in Brugg, Switzerland will continue to operate and all staf will be
press really takes us back to our roots,” retained.
stated Trestad Laser founder Jan Anders-
son. “Several years ago, I took over the Staufen and Schuler are ofering combined consulting and process-optimization
Quintus press operations from Volvo Fly- services for press shops in North America.
gmotor, which now is GKN Aerospace,
Bodycote’s hot isostatic pressing operation in Surahammar, Sweden, earned its
and continued the business within Trestad
Nadcap accreditation. The plant produces Powdermet® near-net shape and selective
Svets, today Siemens Industrial Tur-
surface net shape (SSNS) components for subsea, oil-and-gas, marine, nuclear, tool
bomachinery. steel, and automotive sectors. Bodycote HIP now has nine Nadcap-accredited sites
“The investment also allows us to cer- worldwide.
tify the company according to AS9100,

12 I FORGING I MARCH/APRIL 2018

 Forged
Components
Inc. Confirms
Acquisition
F orged Components Inc., a specialty
manufacturer of stainless steel com-
ponents and products for oil-and-gas and
chemical processing in Humble, TX,
reported recently that it acquired Hous-
ton-based Forge USA in July 2017. Forge
FCI now has over 200,000 sq.ft. of manufacturing
USA, an open-die forging operation, had open-die hammer; a 300-ton ring roll- space for forging, heat-treating, and CNC
filed a Chapter 11 bankruptcy case in No- ing mill; and a range of machine tools. machining at five locations in Texas

vember 2016, claiming liabilities of $10
million-$50 million.
The buyer did not report the value or
other terms of its acquisition.
FCI detailed the assets of its purchase
include 350-ton, 1,750-ton, 2,000-ton
and 3,000-ton open-die hydraulic forge
presses; a 14,000-lb. Chambersburg
The new assets mean that FCI is capable
of producing open-die and semi-closed
die forged shapes weighing from five to
50,000 lbs.
More than this, the Forge USA assets
have added eight more heat-treatment fur-
naces to FCI’s operations in Humble and
Navasota, TX — a total of 300,000 lbs. of
heat-treating capacity. The purchase also
included a 16,000-lbs. polymer-quench
tank and 30,000-lbs. water-quench tank.
In total, as a result of its acquisition,
FCI has over 200,000 sq.ft. of manufac-
turing space for forging, heat-treating,
and CNC machining at five locations in
Texas. …READ MORE

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FORGINGMAGAZINE.COM I FORGING I 13
FIA/FIERF NEWS
FIA’s Forging Technology
Conference Program
T he Forging Industry Assn. has final-
ized the agenda for its 32nd Forging
Industry Technical Conference, which
will take place over two days in Sep-
tember. Forging industry CEOs, plant
managers, technology directors and
managers, plant and chief engineers,
engineering managers, metallurgists,
professors and principals from the re-
sea rch a nd associated gover n ment
agencies and customers are encouraged
to attend.
The Conference will be held at the
Hilton Long Beach in Long Beach, CA,
September 11-12, 2018.
Among the program highlights:
• Industry and technical presentations
covering topics from aerospace and au-
tomotive electrification to lightweight-
ing and additive metal manufacturing;
• Research and student activities at FI-
FIA Calendar
2018 FIA Annual Meeting of
Members
May 5-7
Palm Beach, FL
FIA Automation 101 for Forging
Plant Tours & Workshop
June 6–7
Chicago
FIA Theory & Applications of
Forging & Die Design
June 11-14
Cleveland
FIA & FIERF New Leader
Orientation
August 28
Cleveland
Forging Industry Technical
Conference
September 11-12, 2018
Long Beach, California
2018 FIA Fall Meeting of
Members
October 15-17, 2018
Fort Worth, Texas
14 I FORGING I MARCH/APRIL 2018
ERF magnet school universities;
• An optional plant tour of Weber Met-
als’ new 60,000-ton press, the largest
press in North America.
The two-day event also will include
Aerospace Forging Industry Oversight is
Undergoing a Paradigm Shift
According to Brian Streich of Honeywell Aerospace, chairman of the Nadcap Metallic
Materials Manufacturing Task Group:
T he aerospace forging industry is
continually being regulated, moni-
tored and controlled by numerous orga-
nizations and customers. Aircraft safety
is the key, and the Federal Aviation Ad-
ministration mandates customer over-
sight of its supply base to help ensure
aircraft take off, f ly and land without
failure of components due to manufac-
turing-related defects. This means that
periodic audits are performed by air-
craft and engine manufacturers (OEMs)
on their supply base to make sure all
procedures are being followed and that
the latest part being manufactured per-
forms the same as the first.
Supplier oversight is conducted by
each OEM independently, with no in-
tentional similarities between them.
In 2014, a group of aerospace OEMs
decided that an industry standard for
auditing was needed, and the Metallic
Materials Manufacturing (MMM) task
group was chartered. These companies
were all Nadcap subscribers and saw
an opportunity to use Nadcap to con-
solidate several sets of customer audit
requirements into one. …
The scope of the Nadcap MMM Task
Group includes forgings, castings and
raw material manufacture. Currently,
Nadcap audits can only be conducted
for forging accreditation, while cast-
ing and raw material checklists are still
being developed. The forging check-
list (AC7140) covers: hammer forging;
mechanical presses; screw presses;
hydraulic presses; isothermal presses;
ring rolling; and radial forging.
The forging audit covers the entire
forging process from the purchase or-
der to release of the forgings, including
tabletop exhibits. For sponsorship and
exhibiting opportunities, contact Karen
Lewis at karen@forging.org or 216-
862-6967.
Register online at www.forging.org.
billet cutting and preparation, pre-heat-
ing for forging, forging control, and
post-forging operations, but it does not
cover the special processes that are al-
ready covered by other Nadcap com-
modities such as nondestructive test-
ing, chemical processing, or material
testing.
The creation of the MMM task group
within Nadcap represents a paradigm
shift in how OEMs oversee their forging
suppliers. With this shift comes chal-
lenges, such as: how to keep proprietary
information (both OEM and supplier)
from getting out into the public, what
to do about conf licting OEM require-
ments, and what to do about parts/pro-
cesses from Nadcap subscribers who do
not mandate MMM.
These and other challenges were
overcome by the MMM task group.
A few OEMs have already mandated
Nadcap MMM accreditation of their
aerospace-level forging supply base,
and several more OEMs are expected
to do the same. The MMM task group
members are dedicated to achieving
high quality, consistent audits of their
aerospace-level forgings suppliers that
are as value-added as their previous
independent audits. The MMM task
group members are openly working
with OEMs and forging suppliers to en-
sure that the needs of both are met, and
will continue to be met in the future.
Suppliers and OEMs are encouraged to
join and participate in the MMM task
group, and can learn more at www.p-r-i.
org/nadcap.
Streich will make a presentation on this
topic at the Forging Industry Technical
Conference in September.
NEWS MAKERS

New Officers Intl. Sales & Universal Stainless

for Carpenter Marketing Head Names New CFO
Technology Corp. for Viking Forge U niversal Stainless & Alloy Products
Inc. named Christopher T. Scanlon as

P hiladelphia-based Carpenter Tech-

nology Corp. made two appoint-
ments to its senior operating leadership,
J eff Albee has joined Viking Forge
Corp., Streetsboro, OH, as its new in-
ternational sales and marketing manager,
its vice president of Finance, chief financial
officer, and treasurer. Scanlon has over 18
years of financial experience in corporate,
“consistent with the company’s long-term a position held by Chris DuBiel until his divisional, and public accounting positions.
succession plan.” Joe Haniford, chief retirement in July 2017. Scanlon most recently served as controller
operating officer, assumed a new role as Albee has over 28 years of experience and chief accounting officer of L.B. Fos-
vice president, Business Management in executive management, executive ter Co., a manufacturer and distributor of
Office, and Global bu si ne s s le a d e r- products and services for transportation and
Advanced Engi- ship, and technical energy infrastructure, where he served as
neer ing, as well sales and product acting CFO from April to September 2017,
as the leadership management, in the and oversaw all financial aspects of the
of Environmental, specialty steel mill company.
Health and Safety. manufacturing and From 2009 to 2012, Scanlon was a divi-
His focus will be d ist r ibut ion sec- sion controller for Education Management
on the continued tors. For more than Corp., and he held positions of varying re-
implementation of 20 years, Albee di- sponsibilities with Bayer Corp. and Respi-
Haniford Albee
the Carpenter Op- rected and managed ronics Inc. He began his finance career with
erating Model and d i r e c t s a le s a n d Ernst & Young LLP in Pittsburgh.
Lean manufactur- solution-based technical support for the Scanlon holds a B.S. in Accounting from
ing principles. forging industry. Florida State University and a M.S. in Taxa-
“Joe (Haniford) He will lead the sales and marketing tion from Robert Morris University.
has been an invalu- efforts in North America and globally, “Chris’ highly relevant public company
able contributor to implementing sales and marketing pro- finance experience, his proven track record
our success in el- cesses, procedures and strategic plans for of results along with his energy and focus
evating Carpenter Viking Forge, a precision forging oper- are an ideal match for Universal Stainless
through establish- ation supplying automotive, motorcycle, as we continue to drive the transformation
Murtagh
ing manufacturing aerospace, defense, oilfield, off-highway, of Universal Stainless,” stated chairman,
and safety disci- and material handling markets. president, and CEO Dennis Oates.
plines that have become the foundation of
the Carpenter Operating Model,” stated
Tony Thene, president and CEO. “We New Marketing Director for FIA
thank him for his many contributions as
chief operating officer, and I am pleased
that Joe will continue to be part of the
T he Forging Industry Assn. named Susan Hunter-Vazinski as its director
of marketing, in which position she will be responsible for developing
print and digital membership collateral, website content, and event market-
team.” ing materials. Also, Hunter-Vazinski will serve as FIA’s
Mike Murtagh was appointed vice staff liaison for the FIA Marketing Committee
president and group president of Specialty
Hunter-Vazinski has over 15 years of experience in
Alloys Operations. Murtagh previously
marketing with companies including Fifth Third Bank,
served as Carpenter’s chief technology
Cleveland Magazine, and PNC Financial Services Group.
officer.
Carpenter launched a search for a new In her most recent position she was the marketing di-
CTO. rector for the Precision Metalforming Assn., a trade as-
“Over the last three years, we have ex- sociation representing over 800 stamping, fabricating,
Hunter-Vazinski
ecuted a concerted transformational strat- spinning, slide forming, and roll forming companies in
egy to strengthen our long-term growth North America.
profile and these organizational changes Hunter-Vazinski earned a bachelor’s degree in English with a minor in
are consistent with our leadership transi- communications from John Carroll University.
tion plan,” Thene added.

FORGINGMAGAZINE.COM I FORGING I 15
M AT E R I A L S
Meeting the Automotive
Bar steel products, including forgings,
remain critical to successful automotive
design and production. And there
are opportunities for enhancing that
success.
David W. Anderson
S
teel long products, including bar, rod and wire prod-
ucts, account for about 20 to 25% by weight of the
steel used in North American light and heavy vehicles
based on information provided in a 2010 Mega Associ-
ates study.1 Of this total, more than 85% are parts sourced from
hot-rolled bar products. Parts made from steel bars represent
400-500 lbs. of an average North American vehicle, and this
quantity has remained consistent despite automotive OEMs’ on-
going lightweighting programs. The steel bars are manufactured
into a wide variety of vehicle components, many of which are
forged components, including: gears, connecting rods, crank-
shafts, injector systems, camshafts, hubs, bearings, transmis-
sion shafting, steering racks, steering linkages, stabilizer bars,
constant velocity (CV) joints, drive axles, suspension springs,
and more.
North American steel bar producers provide a wide range of
steel grades with unique chemistries and properties. In addi-
tion, metallurgical processes such as heat treating, thermo-me-
chanical rolling, hot and cold working, and surface hardening,
16 I FORGING I MARCH/APRIL 2018
enable diverse properties in these products. These processes
impart a wide range of new properties from a very ductile,
formable structure to a high-strength product with excellent
fatigue properties.
This wide scope of mechanical properties and the fact that
steel bar production is a proven, high-volume manufacturing
process bodes well for the future of these products’ suppliers,
when considering steel as the material of choice for demanding
automotive part applications.
Steel industry trends/challenges
The automotive industry is striving to reduce vehicle mass in
an affordable way, to improve fuel efficiency while maintaining
or improving safety and performance. In order for them to move
in this direction there is a need to create more power-dense
steel products. Power density is defined by the ability to carry
increased load with the same size component, or the same load
using a smaller-sized component, or a combination of these.
As vehicles are downsized, automotive companies will seek
to optimize component weight by looking for cost-effective
ways to reduce part weight, modify the design of the part, or
consider other lightweight materials. When deciding on the best
lightweighting strategy, it is important to consider all the factors
involved in evaluating a vehicle, such as performance (strength
and durability), vehicle safety, life-cycle environmental impacts,
and the value of the lightweighting approach.
Steel is a proven, high-performance product, is 100% re-
cyclable, and has the ability to be hot forged, cold formed,
Sector’s Future Needs
machined, and extruded into a variety of part configurations. er-density in bar products will support weight reduction at
Steel solutions using these manufacturing processes offer high equal or better performance.
value to the customer, as there are opportunities to optimize Drivetrain systems — The drivetrain generally describes the
manufacturing costs and part performance. components delivering power from the engine to the wheels,
which includes the transmission, driveshaft, differentials, and
Application opportunities axles. Most of the parts used to produce these components are
Manufacturing processes represent a significant portion of sourced from steel bars, which are manufactured into shafts,
the cost of vehicles’ component parts. For example, forming, bearings, and gears.
heat treating and machining can account for as much as 75% of Steering systems — The steering system is an essential part
the part cost. Therefore, it is important for the steel industry to of a vehicle and consists of several critical linkages and compo-
work closely with all participants in the manufacturing supply nents that connect the movements of the steering wheel to the
chain, to deliver components that meet performance, weight, front wheels of the vehicle. These components consist mainly of
environmental, and value requirements. the rack-and-pinion steering, the steering knuckle, control arms,
The Long Products Market Development Group (LPMDG) and tie rods.
is a consortium of steel Chassis and suspen -
manufacturers and their Figure 1 sion system — T he
customers and is part of automobile chassis and
the Steel Market Devel- s u s p e n s i o n s y s t e m’s
opment Institute, a busi- main function is to iso-
ness unit of the American late passengers and cargo
Iron and Steel Institute. from dynamic reactions
This collaborative group of the vehicle as it travels
has updated its Auto- the road surface. Above
motive Roadmap which all else, safety and du-
identifies technical chal- rability control suspen-
lenges and research op- sion design and material
portunities in steel bar choices. The system con-
product metallurgy, en- sists of vehicle structural
abling processes, steel support components, in-
Figure 1. An internal combustion engine with key components (highlighted in red)
characterization, and part where steel is currently used and likely to remain as engine size decreases and power cluding the suspension
design. A summar y of requirements increases.2 springs, strut rods, and
this roadmap outlines the stabilizer bars, as illus-
opportunities for bar steel trated in Figure 2.
in various applications, material development and manufactur-
ing technology, to support the continuing need for improved Material development
performance and lightweighting in the automotive industry. There also are improvements in other material characteristics
Engines — Automotive engines offer the greatest opportu- of steel, such as fatigue and toughness, which can support im-
nity for improved fuel economy through mass reduction and provements in power density.
increased efficiency. As internal combustion engines become Gear steels with bending and pitting fatigue resistance
smaller and generate more power, this will result in increased — Gear manufacturers and users are continually seeking
loads and stresses. This increase in power density for these improvements in material performance, in order to increase
components creates large potential for more forged steel com- the power density of individual components and associated
ponents. Higher-strength steel components such as crankshafts, systems. For example, automotive transmission manufactur-
connecting rods, camshafts and pistons as shown in Figure 1 ers would like to double the torque capability over the 10-year
will be needed. life of a given transmission. Improvements to the resistance
In addition to opportunities in engine applications, there to both bending and pitting fatigue properties of steel grades
are many other components of the powertrain system, along are needed to meet these and other similar goals for higher
with chassis and suspension systems, where increased pow- performing gear in various market sectors.

FORGINGMAGAZINE.COM I FORGING I 17
M AT E R I A L S
Figure 2
Figure 2. A rolling chassis with critical components (highlighted in red) where steel is used currently,
and likely to remain.
As-forged higher strength steels with high toughness
— Hot-forged, air-cooled micro-alloy steel forgings meet
the strength and fatigue properties equivalent to heat-treated
parts. Micro-alloying precipitation strengthening technol-
ogy has the potential to provide forged components with
increased mechanical properties, to allow part lightweight-
ing without the need to heat-treat the forging. A significant
benefit of this technology is a lower part-manufacturing cost
resulting from eliminating heat treating.
However, these micro-alloyed steels are not used to their
full-strength potential, as their toughness tends to be lower
than acceptable for a similar chemistry, heat-treated steel
part. The development of as-forged steels with a higher level
or improved balance of toughness and strength would expand
the application of as-forged steels.
Manufacturing technology opportunities
All cold, warm, and hot forming operations have the ad-
vantage over castings and machined bar stock in controlling
the deformation and metal f low to increase metallurgical
soundness and improve mechanical properties. This can im-
prove directional grain f low (anisotropy) where needed for
maximum part strength, and provide better fatigue resistance
and impact toughness on part sections, such as gear teeth. Ad-
ditional research and development opportunities to improve
forming technology and costs include:
Cold forging research
and development focus
• Upgrade simulation software to predict breakage or lubri-
cation failure;
• Develop test method to evaluate effectiveness of lubrica-
tion prior to part production;
• Create additional test method to evaluate formability prior
to running production parts (cold upset test is satisfactory for
certain applications); and,
• Further enhance deep rolling to apply its strengthening
benefits to other components.
18 I FORGING I MARCH/APRIL 2018
Warm forging research
and development needs
• Improve die coatings and lubricants to
better facilitate extrusion at higher tem-
peratures; and,
• Develop warm temperature steel prop-
erty data to improve computer simulation.
Hot forging research and development
focus
Optimize reheating processes to allow
better temperature control and avoid grain
coarsening;
• Develop scale-free reheating;
• Improve die coatings for high forging
temperatures;
• Enhance modeling of non-uniform
cross-sectional heating on metal flow,
especially in automated multi-sequenced
forging;
• Create a vision system to monitor part-size tolerances and
surface defects at high forging temperatures and high pro-
duction rates.
Other manufacturing technologies
In addition, for improvement in forming processes to help
meet automakers’ needs, there are manufacturing improve-
ment opportunities, including:
• Improve machinability to reduce manufacturing costs re-
lated to forged components;
• Develop more competitive near-net shape forging oper-
ations to reduce the amount of metal removal during ma-
chining;
• Use enabling processes, such as surface hardening or coat-
ings, to improve fatigue strength and resistance to surface
wear on moving components; and
• Enhance fillet strengthening techniques to allow for higher
strength levels in this fatigue-sensitive location.
The LPMDG Automotive Roadmap identifies numerous
current technical challenges and research opportunities in
steel bar product metallurgy, enabling processes, steel char-
acterization and part design. The LPMDG uses this roadmap
to define projects and has found working in collaboration
with OEMs, Tier 1 and 2 customers offers the best opportu-
nity to meet the automotive industry performance, fuel effi-
ciency and value required for future applications.
David W. Anderson is the senior director of the automotive
market and long products program at the Steel Market Devel-
opment Institute. Contact him at danderson@steel.org.com
or, learn more about the LPMDG Automotive Roadmap at www.
autosteel.org
1. Great Designs in Steel 2014, Advanced Steel Offers Automakers
Aggressive Engine Downsizing (A. Schmitter, Nucor Corp.)
2. Steel Content of North American Vehicles Year 2010, Mega Asso-
ciates / AISI.
O P E R AT I O N S

Expanding and Flexing

Heating Processes
TimkenSteel’s new AQTF adds capacity and functionality to the task of heating
quality steel long products

A
s noted by the Steel Market Development Institute, steel The new line is able to treat 10 tons per hour of bars and
manufacturing processes represent a significant portion heavy-walled tubes, up to 13 inches in diameter, in strict com-
of the value imparted to engineered automotive parts, pliance with specified values, according to SMS.
creating the basis from which processes like forging can com- “We found that SMS was able to bring the best technology to
plete the value proposition. One of the top suppliers of forging meet our needs and satisfy our customer demand. The commis-
raw materials is TimkenSteel, which produces up to 2 million sioning effort went very well,” according to Carolee Vanicek,
tons/year of carbon steel, alloy, and micro-alloyed steel for director of tube manufacturing there.
automotive, oil-and-gas, During the line commis-
and general industrial sioning last year, a wide
applications. Since it array of intensive tests was
was launched in 2013 carried out. This included
t he Oh io st eel ma ke r certification of the combus-
has been investing in its tion heating furnaces in line
production capabilities, with the SAE ASM2750-E
continuing to build the standard, which calls for
means for manufactur- extremely demanding tem-
ing high-quality prod- perature homogeneity (±
ucts that will ensu re 3°C for furnaces of Class
the value of the compo- 1), as a requirement for pro-
nents produced in the ducing aerospace-quality
next phase of the supply material.
chain. According to the new
The Advanced Quench-and-Temper Facility designed and built by SMS group
L a t e l a s t y e a r for TimkenSteel will process 50,000 tons/year of 4- to 13-in. bars and tubes, for line’s developer, a range
TimkenSteel completed automotive, oil-and-gas, and general industrial applications. of seamless mechanical
the product testing tubes and SBQ (Special Bar
phase for its Advanced Quench-and-Temper Facility at the Quality) products have been processed by the AQTF, from 6 to
Gambrinus Steel plant in Canton, OH — a project first an- 12 in. (beyond the specified range of 4 to 13 in.) These include a
nounced in 2015 as a $40-million investment for induction wide variety of different steel grades, reflecting TimkenSteel’s
preheating and heating furnaces, to austenitize and temper portfolio. The tests were performed with increasing rates of
4- to 13-in. bars and tubes at a rate of 50,000 tons/year. hourly throughput, to “stress test” all the line components.
The AQTF was designed and built by SMS group, which The AQTF start-up was a something of a finale for Timken-
gained the Final Acceptance Certificate for the project from Steel’s centennial celebration during 2017 (reflecting its long
TimkenSteel last November. history as a Timken operation), and followed a series of capital
SMS designed the compact installation to impart specific investments it has made in recent years to expand and improve
levels of mechanical strength to various steel grades and prod- its production capabilities: the 3,300-ton inline forging process
ucts. The line includes a combination of induction preheaters in 2012; an intermediate finishing line for seamless tubes in
and combustion furnaces – which impart the austenitizing 2013; and a jumbo vertical bloom caster in 2014.
and tempering effects to the various steel grades. The walk- “Everyone has risen to the challenge for improving safety,
ing-beam furnaces heat the bars or tubes to a uniform tem- quality and efficiency,” Vanicek said of the latest Gambrinus
perature, usually over 1,500°F, followed by quenching in a hot plant expansion and process improvement. “The areas work to-
liquid (usually oil or water), or air, depending on the grade. gether to benchmark one another and develop strong solutions
Subsequent product cooling takes place in a newly devel- for improvement.”
oped “quenching shell,” an advanced OD/ID water sprayer, While the current advances emphasize heat-treating capac-
characterized by high-quench severity and, at the same ity and flexibility, Vanicek foresees the TimkenSteel opera-
time, flexibility for adapting the process according to prod- tions “continuing to serve evolving and challenging markets
uct requirements. with the best value-added long products.”

FORGINGMAGAZINE.COM I FORGING I 19
LAST YEAR’S
BUYER’S GUIDE
WAS A PAGE TURNER!
SUPPLIERS
M A N U FA C T U R E R S
M AT E R I A L S
E QU I P M E N T
SUPPLIES
SERVICES
BE A PART OF
THIS YEAR’S BUYER’S GUIDE
RESERVE SPACE FOR
YOUR COMPANY NOW
DEADLINE IS SEPTEMBER 5TH
CONTACT

JOE DINARDO
440.487.8001
JOE.DINARDO@INFORMA.COM
SUCCESS STORY

New Multi-Directional Press at ECG

Ellwood Crankshaft Group is now able to forge crankshafts up to 14 m long
and weighing up to 50 mt.

T he Ellwood Crankshaft Group plant in Sharon, PA, is the

site of a landmark new forging system, a 35x35-m. multi-di-
rectional press that expands the group’s already wide range of
ing crossheads; the clamping, offset axis has two 75-MN op-
posing crossheads. Independent servo drives control 24 axes for
position, speed, and pressure. The forging and decompression
highly engineered crankshaft products — which power engines cycle controls ram parallelism and off-center loading.
used in locomotives, marine vessels, oil-and-gas exploration, Ellwood Crankshaft Group (ECG) is an integrated manufac-
power generation, and heavy-duty mechanical presses. turing operation, with carbon, alloy, stainless, and tool steels
p ro d uc e d by El lwo o d
Qualit y Steels in New
Castle, PA. The forging
capabilities include three
multi-directional closed-
die, forging presses. ECG
also is equipped to per-
form welding, heat treat-
ing, surface engineering,
and f inish machining,
according to the needs
of specif ic cran kshaf t
desig ns as well as the
group’s remanufacturing
services for crankshafts
and connecting rods.
The new multi-direc-
tional press had been in
development for much of
the past decade. The ma-
chine was designed and
The 35x35-m, 8.5-m high press has two 80-MN opposing crossheads in the upset axis, and two 75-MN opposing crossheads built by a European ma-
in the offset axis
chine builder, after which
“This is the first time we will have the ability to produce the followed an extended sequence of construction and then testing/
full range of continuous grain-flow, forged crankshafts in sup- acceptance processes.
port of the world markets,” according to ECG president Brian While ECG continues to have available its previous multi-di-
Taylor. “We are now able to supply the full range of continuous rectional forging systems, able to produce continuous grain-
grain-flow crankshafts to every industrial market in every re- flow crankshafts up to 6 m long and weighing 6 metric tons,
gion of the world.” mainly for engines, the new press is able to forge crankshafts
The new press entered into operation early last year, with up to 14 m long and weighing up to 50 mt. This covers a new
its first project being a 300-mm bore crankshaft for a large gas range of crankshaft applications, for larger engines, pumps, and
engine. compressor systems.
Developed over a period of years, the 35x35-m, 8.5-m high The new press also can process other large, complex
press is set in a 6,000 m 3 foundation. It has 317.5 metric tons shapes, meaning ECG is able now to transform open-die
of vertical, horizontal and circumferential post-tensioning ten- forgings, large complex castings, and welded structures into
dons; 771 mt of reinforcement; and a self-contained hydraulic new designs. This may include forged eccentric shapes, rect-
system, with three pairs of motors and pumps. It also has four, angles, cylinders, and flanges, for products like pinions, tur-
3-MW electrical sub-stations for each hydraulic aggregate. bine rotors, tie and tension rods, shafts, special cups, single or
The upset axis of the new press involves two 80-MN oppos- multiple cams, blocks, and couplings.

FORGINGMAGAZINE.COM I FORGING I 21
SAFET Y

Five Trends
to Watch in Machine Safeguarding
Manufacturing equipment builders are important contributors to the development
and implementation of safety standards, including setting new strategic objectives.
Carrie Halle

I
ndustrial safety standards are not fixed objects. They are frontier in manufacturing applications. Appropriately, their use is
dynamic principles that evolve as manufacturing processes being reflected in safety standards.
and equipment changes, and as more information becomes RIA TR R15.606-2016 — Collaborative Robot Safety (“TR 606”)
available to the operators and managers. Manufacturing permits a cobot system and operator to share the same work area
equipment builders are important simultaneously without the burden-
contributors to the development and some use of safety fencing. This tech-
implementation of safety standards, nical report offers new clarification
and Rockford Systems is highlighting of the four different types of collabo-
five machine-safeguarding trends that ration: Safety Monitored Stop, Hand
are strategic objectives now for man- Guiding, Speed & Separation Moni-
ufacturers in 2018. Each one of these toring, and Power & Force Limiting.
has the potential to influence signifi- Because cobots are affordable, highly
cantly or even to disrupt established adaptable, and almost plug-and-play,
processes — and may present a new manufacturers are eager to integrate
need for investment by manufacturers this technology into their processes.
that risk being out of compliance with 2. Laser-guided safety — Press
Laser AOPDs allow the operator to work in very close proximity
newer OSHA/ANSI codes, or being of the point of hazard. brakes are “ unforgiving ” machin-
too late to adopt productivity-enhanc- ery, and a frequent cause of work-
ing equipment. place amputations of hands and fingers. U.S. Department of Labor
1. Robots and cobots on the move — U.S. manufacturers are ac- statistics indicate an average of 368 instances of amputations annu-
celerating their use of robots and cobots, and that trend will continue ally from press brake accidents. There are a number of press brake
over the next decade as these units become less expensive and more safety options, ranging from barrier guards and pull-backs, to light
effective at performing more tasks. curtains and two-hand down/foot devices.
According to the Robotic Industries Association (RIA), the North The more recent entry into the press-brake safety category is
American robotics market broke records for orders and shipments probably its most revolutionary: The Laser Active Optic Protective
in 2017. As robots and cobots find homes in shops of all types and Device, more commonly referred to as the AOPD. Invented in 1998
sizes, manufacturers need to ensure these pieces of equipment are as an alternative to light curtains, these systems were first used in
integrated properly to their production sequences, and that they are the European Union before coming to the U.S. in 2003 as a retrofit
adequately safeguarded per ANSI/RIA R15.06-2012. solution.
For robots, incorporating a combination of safeguarding equip- Laser AOPDs allow the operator to work in very close proximity
ment, such as perimeter guards, light curtains, pressure-sensitive (15 mm) to the point of hazard. This improves the productivity of
safety mats, and laser scanners, is an essential piece of the puzzle, but the press brake significantly by increasing cycle time and reducing
it’s not the only measure needed to ensure safe operation. operator injuries and fatigue. AODP is best suited for applications
According to the Occupational Health and Safety Administration such as box bending, bending with flanges, or where light curtain
(OSHA), many robot accidents occur during non-routine operating effectiveness is diminished due to excessive blanking or muting.
conditions, such as maintenance, programming, setup, or adjust- The recent inclusion of Laser AOPD technology in the B11.3 is a
ments. More often than not, these accidents — which can result in welcome addition to the standard that now gives press brake man-
injury or death — are preventable. ufacturers, dealers and users a clear guideline to implementing this
Safeguarding equipment is not a one-size-fits-all solution. The technology safely.
best way to safeguard your robot is to observe the machine while 3. Putting the world on guard — Rapid industrialization across
it operates, evaluate all of the variables around it, and then use that the world, particularly in developing regions, is propelling the de-
feedback to design a system unique to that robotic cell. Some man- mand for machine safeguarding. Developing economies in China
ufacturers opt to have their robots safeguarded before they arrive on and India are increasingly adopting modern machine safeguarding
the shop floor. That’s a great idea in theory, but there are risks. techniques. More sophisticated management, new stringent regula-
Collaborative robot systems or “cobots” are opening up a new tions, and the presence of various multinational companies in these

22 I FORGING I MARCH/APRIL 2018

countries is increasing emphasis on the use of safeguarding systems key-controlled locks, control switches, interlocked guards, remote
to align with business goals. Despite the current, overall economic devices and disconnects. It can also mean locking out just a section
slowdown in China, for example, the machine safeguarding market of a piece of equipment, rather than the entire machine. Implement-
continues to perform well in this region. ing alternative procedures to ensure equivalent protection for spe-
4. Alternative universe — Once you know its intricacies, it is cific tasks is enhancing productivity without endangering employ-
understandable why LOTO, as outlined in OSHA standard 29 CFR ees. But those procedures — and their benefits — come with strings
1910.147 “The Control of Hazardous Energy attached, requiring a thorough understanding
(Lockout/Tagout), has become an everyday According to the of the latest OSHA and ANSI standards.
struggle for many safety personnel. It can be Occupational Health and 5. Automation lowers costs — The Dar-
very time-intensive, often requiring longer Safety Administration winian concept of “adapt or die” is on the
than is required to finish the actual mainte- mind of every manufacturing executive, es-
nance task on the machine. Production comes (OSHA), many robot pecially machine builders who seek to re-
to a halt, resulting in the day’s production accidents occur during main vital in a competitive global market.
numbers potentially being missed. This be- non-routine operating Automation technologies and the Industrial
comes even more frustrating when the main- Internet of Things are helping to lower the
tenance task is one that must be implemented conditions, such as costs of integrating safeguarding equipment
several times a day. Loss of time and profits maintenance, programming, in production machinery, such as presses,
create a strong incentive to bypass LOTO to setup, or adjustments. milling machines, and lathes. Savings are be-
carry out repetitive machine tasks. ing realized in improved productivity, leaner
Thankfully, OSHA 29 CFR 1910.147 also outlines “Alternative inventory management, and preventive maintenance.
Protection Measure” (APM) procedures that can result in increased For machine builders, including safeguarding is increasingly
efficiency without compromising the safety of the operation. This emerging as a key competitive differentiator, one that is becoming
exception is also referred to as the “minor servicing exception.” more affordable to offer to their customers.
Designed for machine tasks that demand frequent repetitive access, Carrie Halle is v.p. of marketing for Rockford Systems LLC, with over
i.e., clearing a jam on a conveyor or a minor tool change, Alternative 25 years’ experience in global business planning, branding, product
Measures do not require that power sources be completely cut off. management, and marketing communications. Contact her at carrie.
Examples of Alternative Methods technology may include halle@rockfordsystems.com

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FORGINGMAGAZINE.COM I FORGING I 23
NEW PRODUCTS
Flexible
Microfinishing Cuts
Manufacturing
Cost
IMPCO — Industrial Metal Products
Corp. — offers a new-design, CNC mi-
crofinishing system that polishes cy-
lindrical bearing journals of a range of
different size crankshafts to micron tol-
erances, consistently and automatically,
The IMPCO Worldstar 1680 machine processes
a 4-cylinder crankshaft through three levels of
microfinishing plus thrust face finishing. In the
automotive industry, surface finish parameters
used to evaluate the surfaces of the crankshafts
include Ra, Rk, Rpk, and Rvk.
without the need to manually change
and reposition the tooling, reducing
changeover time from hours to minutes.
IMPCO says its Worldstar 1680 is the
first fully flexible microfinishing sys-
tem for the automotive industry, built
to the requirements of a European auto-
maker for installation in Brazil.
Microfinishing is the process that
removes the microscopic amorphous
surface material left from the grinding
of a dimensionally finished part, such
as a cran kshaft, camshaft, or pump
24 I FORGING I MARCH/APRIL 2018
shaft, to permit a highly precise fit to
a mating part.
IMPCO microf inishing generates
the f inal functional surface texture
required for friction reduction, higher
performance, and greater reliability of
the precision shafts. Microfinishing tol-
erances are unattainable with grinding.
“In today’s automotive engines, the
surface texture on these functional key
features on the internal engine compo-
nents are microfinished to very fine tol-
erances that enable combustion engines
to operate more efficiently and to meet
emissions, horsepower and fuel econ-
omy goals,” said Mark Hendel, IMPCO
global sales director.
In the microfinishing process, abra-
sive film is fed through a pair of op-
posed arms, each holding tooling that is
shaped to fit over the part’s cylindrical
bearing journals. During the process,
the ar ms close around the jour nals,
holding the film against the rotating
part for a specified time to achieve the
desired surface texture.
The part may undergo several in-
creasingly fine levels of finishing to
produce the final finish.
The IMPCO machine processes a
4-cylinder crankshaft through three
levels of microfinishing plus thrust face
finishing. In the automotive industry,
surface finish parameters used to eval-
uate the surfaces of the crankshafts in-
clude Ra, Rk, Rpk, and Rvk.
The f lexibility of the machine to
position any of its 11 pairs of arms au-
tomatically, in any position to accom-
modate a range of crankshaft sizes will
save time during changeover and avoid
the need to retool the machine. The
machine will permit the automaker to
produce any crankshaft in its matrix
of part dimensions, including variation
on bearing pitch (main bearing to pin
bearing spacing), currently and into the
future.
Each microfinishing station in the
four-machine system is loaded and un-
loaded automatically with an overhead
gantry. … READ MORE
Cold Forming
with Minimized
Changeover
HATEBUR is introducing a new cold
forming machine for high-precision parts
from 8 to 125 mm long and up to 22 mm di-
ameter. The COLDmatic CM 725 is a sev-
en-station process machine recommended
for automotive industry suppliers.
“Our engineering team implemented
The Hatebur COLDmatic CM 725 is a seven-station
process machine recommended for automotive
industry suppliers.
several innovations to make our clients
more efficient and productive,” stated Re-
inhard Buehrer, who heads marketing and
sales programs for the Swiss machinery
developer. “With a production capacity of
up to 180 parts per minute, the CM 725 is
much faster than previous machine gen-
erations.”
In addition to process speed, the new
Hatebur system minimizes the change-
over times: At the wire in-feed, a linear
servo-motor ensures that the grippers
push the wire forward with exceptional
precision.
“The volume variation of the cut-off
parts is below 0.35%. Together with
the high quality of the sheared surface,
which is typical for the COLDmatic, this
results in a cut-off quality that allows
forming from the first station,” accord-
ing to Buehrer.
The significant new aspect of this
COLDmatic machine is the newly de-
signed transfer-system on which the grip-
pers for the part transfer are mounted: All
grippers are individually driven by servo
motors, and can be individually opened
and closed as well as programmed. “This

programmability brings enormous advan-
tages when it comes to changeover times.
Instead of changing all the parameters
manually, all previously saved settings can
be applied in just a few seconds,” Buehrer
explained.
Because of the ser vo motors, the
COLDmatic CM 725 uses many fewer me-
chanical parts than previous machines,
reducing the overall costs by almost 20%.
The fast changing system allows opera-
tors to lift out all seven punches and dies
at once and exchange them with prepared
units. All tools can be exchanged in only
ten to fifteen minutes.
… READ MORE
More New Forging
Technologies
… READ MORE is your tip to
visit forgingmagzine.com/
new-products for up-to-date,
extensive, informative reporting
on news and developments for
forging operations, including …
• Cold Forming with
Minimized Changeover
• Wireless Lubrication
Monitoring
• Heavy-Duty, Inert
Atmosphere Furnace
• Purpose-Designed, Water-
Based Cleaning Systems
• Flexible Microfinishing Cuts
Manufacturing Cost
• High-Speed Automatic
Sawing System
• Thermal Imaging Detectors
• High-Speed Automatic
Sawing System
• Data Transfer for Bandsaw
Blade Cutting Parameters
• Large-Area Spray Nozzle
Covers 360 Degrees
• Servo-Driven Mechanical
Forging Press
• Pressure Blasting for Large-
Part Cleaning  4 in. of 1,900°F block insulation.
• High Productivity for
Handheld Scanning
• Trimming Presses for
Custom Forgings
• Precision Flange Facing Tool
…READ MORE informative and timely reporting on technology for
forging operations at forgingmagazine.com/new-products
Heavy-Duty,
Inert Atmosphere
Furnace
GRIEVE CORP. is offering a 2,000°F
(1093°C), inert-atmosphere, heavy-duty
furnace for heat-treating high-performance
engineered parts, such as turbine com-
This Grieve inert-atmosphere furnace has a
roof-mounted, heat-resisting alloy circulating
fan powered by a 1-HP motor with V-belt drive,
water-cooled bearings, and inert atmosphere
shaft seal.
ponents. Workspace dimensions of mea-
sure 36x60x36 in. (WxDxH.) 73 KW are
installed in ICA wire coils supported by
vacuum-formed ceramic fiber installed on
all interior surfaces, including the door and
beneath the hearth.
This furnace has a roof-mounted,
heat-resisting alloy circulating fan powered
by a 1-HP motor with V-belt drive, wa-
ter-cooled bearings and inert-atmosphere
shaft seal. Furnace features include 9-in.
thick, insulated walls comprised of 5 in. of
2,300°F ceramic fiber and 4 in. of 1,900°F
block insulation; 8.5 in. floor insulation
comprised of 4.5 in. of 2300°F firebrick and
Other features include 0.25-in. plate ex-
terior reinforced with structural steel, 0.5-
in. steel face plate at the doorway, with an
air-operated vertical lift door.
The inert-atmosphere construction in-
cludes a continuously welded outer shell,
FORGINGMAGAZINE.COM I FORGING I 25
high-temperature door gasket, sealed heater
terminal boxes, inert-atmosphere inlet, in-
ert-atmosphere outlet, inert-atmosphere
flow meter, and a manual gas valve.
Controls for this design include a digi-
tal programming temperature controller, a
manual reset excess temperature controller
with separate contactors, paperless event
recorder, and SCR power controller.
… READ MORE
Purpose-Designed,
Water-Based
Cleaning Systems
ECOCLEAN INC. offers machine op-
tions for aqueous media part cleaning, from
coarse through intermediate to fine and
ultrafine cleaning. Optimal adaptation to
The EcoCflex 3 enables users to realize high- and
low-pressure processes as well as injection flood
washing in one cleaning station.
the tasks and demands of distinct industries
is key to superior cleaning quality, higher
process reliability and plant availability, in
addition to saving costs and resources.
EcoCflex 3 – Short cycle times and high
flexibility have made robot cells indispens-
able for preliminary, intermediate and final
cleaning of engine and transmission parts,
such as cylinder heads and crankcases. The
EcoCflex 3M/3L sets new standards for
such cleaning systems, first because of its
SCARA manipulator developed specif-
ically for use in cleaning equipment, re-
placing the conventional adapted six-axis
articulated arm robot. Thanks to its rugged
design consisting of high-strength alumin-
ium and high-grade steel, augmented by an
IP 69 protection class rating, the unit resists
high-pressure water jets and is submersible.
NEW PRODUCTS

EcoCwave sealed chamber — EcoCwave is designed with a 1100 Superior Avenue • Cleveland, OH 44114-2521
vacuum-tight work chamber for immersion and spray processes Tel.: 216-696-7000 • Fax: 216-696-7932 • TWX: 810-421-8245
ranging from coarse through intermediate to ultra-fine cleaning.
It is equipped with two or three tanks as standard, depending on BUSINESS STAFF
the application. The tanks are mounted upright and are flow-op-
Paul Miller paul.miller@penton.com
timized to prevent formation of chip or dirt pockets. In addition,
President – Industry & Infrastructure 510-423-0331
each tank has its own separate cleaning fluid circuit with full-flow Informa Business Intelligence
and bypass filtration. Thanks to an optimized rollover unit in
Jacquie Niemiec jacquie.niemiec@penton.com
the work chamber, the fluids and mechanical cleaning devices
Senior VP, Marketing- Industry & Infrastructure 216-931-9585
(e.g., ultrasonic units and spray nozzles) can reach the product
effectively from all sides. This helps to improve cleaning quality Frank Chloupek frank.chloupek@penton.com
Audience Marketing Director 216-931-9484
but also tangibly increases the fluid lifetime, thereby reducing
cleaning costs. Brenda Wiley brenda.wiley@penton.com
Production Manager 913-967-1805
EcoCcube chamber system — The various tasks related
to degreasing, intermediate, and fine-cleaning of parts across
a broad range of general industry applications are covered by
SALES OFFICES
Ecoclean with a range of different water-based cleaning systems.
Joe DiNardo U.S. and Canada
The EcoCcube, an entry-level model, is suitable for a variety of joe.dinardo@penton.com
functions. With installation dimensions of only 2,100 x 1,630 x Tel.: 440-487-8001 • Fax: 913-514-3896
1,855 mm (LxWxH) in addition to low weight, this compact unit
Julian Maddocks-Born U.K., Europe
can be integrated into a manufacturing line easily and in mini- Julian@itsluk.com
Tel.: +44-1442-288-299
mum time. The perfectly adapted size of its two standard flood
tanks mean that it reaches its operating temperature quickly and Yanru (Lucy) Han China, Hong Kong, Taiwan
HYR@leegn.com
energy-efficiently. … READ MORE Tel.: +86-10-571-57202 • Fax: +86-10-511-85828

Yoshinori Ikeda Japan

Wireless Lubrication
Tel.: +81-3-3661-6138 • Fax: +81-3-3661-6139

Cesare Casiraghi Italy

Monitoring c.casiraghi@tin.it
Tel.: +39-031-261407 • Fax: +39-031-261380
The ASSALUB AB WLubeMon system ensures that the right
amount of lubricant is fed at the right time to the bearing, the funda-
mental standard for reliable lubrication. The system works completely REPRINTS, CUSTOMER SERVICE, and CONTENT USE
independently and Reprint Services Wrights Media
is capable of mon- Tel.: 877-652-5295
reprints@pentonreprints.com
itoring all types of
Customer Service Tel. 800-262-1954/ Fax: 913-967-1901
lubrication systems, customersupport@penton.com
including manual lu- PO Box 12901, Overland Park, KS 66212-2901

brication. List Rentals Justin Lyman

Tel.: 913-967-1377
T he Lub eMon justin.lyman@penton.com
meter has been avail- National Archives (NAPC) Microfilm Copies
The WLubeMon system is comprised of a
precision lubricant meter that communicates able previously —
with a control unit on a regular basis, wirelessly. but with cable trans-
mission. This led to
disadvantages that included the cost of cable installation and the risk
of cable damage. Tel.: 1-800-420-6272, ext. 6578
1166 Avenue of the Americas • 10th Floor• New York, NY 10036-2708
The WLubeMon system is comprised of a precision lubricant Tel.: 212-204-4200 • Fax: 212-206-3622
meter that measures the amount of lubricant fed into the lubrication
INFORMA MEDIA INC. CORPORATE OFFICERS
point. The meter communicates with a control unit on a regular ba-
Patrick Martell Chief Executive Oficer
sis, wirelessly. The system provides alarm both for too high and too Paul Miller Group President, Industry & Infrastructure
low lubricant volume, as well as statistics and log functions.
Printed in U.S.A. • Copyright © 2018 Informa Media Inc.
The control unit can monitor up to 20 individual meters and All Rights Reserved
normally has a carriage of 75 meters. The condition for each meter FORGING is indexed in the Applied Sciences and Technology Index and with the Engineering Index gen-
erally available in libraries. Copying: Permission is registered with the Copyright Clearance Center Inc. to
is shown clearly on the control unit. The control unit is very us- photocopy any article, with the exception of those for which separate ownership is indicated on the first
page of the article, for a base fee of $1.25 per copy of the article, plus $.60 per page, paid directly to the CCC.
(Code No. 0360-8999/97 $1.25 + $.60)
er-friendly and has a color display.
The battery is rated to last at least 15 years. … READ MORE

26 I FORGING I MARCH/APRIL 2018

 FORGING INDUSTRY SPECIALIST
NATIONWIDE SEARCH & RECRUITMENT
• OPERATIONS • ENGINEERING
• MAINTENANCE • SALES • QUALITY
• METALLURGY • EXECUTIVE
Bradley E. Stiles • 610-351-8070
BStiles@UnitedEmploymentGroup.com
www.UnitedEmploymentGroup.com
PHOENIX INDUCTION CORPORATION
• Large inventory of OEM
parts, as well as other
manufacturers, AJAX*,
AIH*, Bone Frontier*,
IEH*, and Robotron*
• SCRs, Diodes,
Transistors,
IGBTs, Capacitors,
Transformers, and
much, much more
• Provide you with
fast turnaround and “an induction supply company”
decreased down time
248-486-8760
www.phoenixinduction.com
sales@phoenixinduction.com
*RegisteRed tRademaRks of theiR Respective companies

• Hydraulic • Open Die • Rebuilding

• Mechanical • Repair • Custom to
• Closed Die • Upgrade 15,000 tons

ISO9001: 2OO8 CertiÀed

Toll Free: 800-222-3608
Phone: 814-455-3941
www.eriepress.com

CONTACT:
ER TI SEJoe DiNardo
IADVN THE
440.487.8001
PRODUCT joe.dinardo@informa .com
EXPRESS
ADVERTISER INDEX |
ADVERTISER PAGE WEBSITE
AJAX - CECO 23 www.ajax-ceco.com
BEHRINGER SAW INC. 13 www.behringersaws.com
COR-MET INC. 1 www.cor-met.com
ELECTRALLOY BC www.electralloy.com
FINKL STEEL IFC www.finkl.com
FORGING 2018/19 BUYERS’ GUIDE 20 http://directory.forgingmagazine.com
GERDAU 7 www.gerdau.com/northamerica
GREENLEAF CORPORATION 8-9 www.greenleafcorporation.com
IW MFG & TECHNOLOGY CONFERENCE & EXPO. IBC www.mfgtechshow.com
LASCO ENGINEERING SERVICES 3 www.lascousa.com
SUMMIT STEEL CORPORATION 11 www.summitsteel.com
WELD MOLD CO. 5 www.weldmold.com
Every effort has been made to ensure the accuracy of this index.
However, the publisher cannot be held responsible for errors or omissions.

FORGINGMAGAZINE.COM I FORGING I 27
PICTURE THIS

Iron and Steel, Art and Craft — and Learning by Doing

New book explores the science and art of blacksmithing, as well as the methods
for executing the craftsman’s vision
Techniques — like hand forging —
are learned by experience, but a
clear understanding of the process
and a vision for the result are
essential to the blacksmith’s craft.
Sully Sullivan Photography
ous training and schooling to see if I could
make a career of it.”
Most readers will realize we are living
in a high-tech, immediate-results age —
which has only magnified the accomplish-
ments of true craftsmen. Robert Thomas
pursued his interest to The National
School of Blacksmithing in Hereford, En-
gland, where he studied traditional forg-
ing techniques. Now he oversees a custom
ironworking shop and studio in Charles-
ton, SC, where a team of blacksmiths take
on complex projects and create work of
exceptional artistry.
“We are currently working on several
projects,” he reported: “A really unique,
sculptural table base, a forged railing, a
lighted chandelier and matching set of
door handles, and a range hood.” The shop
also has steady work producing forged
products, like shelf brackets.
Readers will see the results of Thomas’
training, and his vision — and may learn

M odern tastes may run closer to the wisecrackers on TV’s some techniques in pursuit of their own visions. But the work con-
Forged in Fire than to Longfellow’s The Village Blacksmith, tinues. This craft is not a calling that can be answered quickly.
but the idea that there is knowledge and understanding to be gained “Lately I’ve been very interested in using industrial forging tech-
by watching a craftsman at work is apparently timeless. niques to make architectural forged elements,” Thomas explained.
Thus at the flaming forge of life “We have four power hammers in the shop, and look to the forging
Our fortunes must be wrought; industry for ideas to develop tooling and techniques to streamline
Thus on its sounding anvil shaped our small, architectural forging processes.”
Each burning deed and thought. Industrial forging may rely more on science and engineering
“The Art & Craft of the Blacksmith,” a handsome new volume than on skill or artistry, but there is a link between the two that this
by Robert Thomas, will appeal to both sensibilities, as well as to blacksmith would like to strengthen. “What they do is awesome,”
anyone working in industrial forging who may be similarly allured Thomas confirmed. “Our forging process is essentially the same,
by the transformation of a cold metal form into something elegant only on a smaller scale. I would love to try out industrial forging
and functional; or, drawn to the mystery that unfolds as the artisan’s one day.”
vision and strength convert a lifeless shape into something vital and While his book is presented as a guide for “craftspeople making
enduring. We learn from Thomas’ insights as well as his example, the transition from interest to hobby”, Thomas also aims to influ-
because to understand the craft, watching is not enough. One has to ence anyone seeking to go further, as in vocational training.
take up the work. “A huge driving force in writing this was taking the opportunity
“I always loved working with my hands, and loved metal since to create a true reference book for someone serious about learning
I learned to weld in high school, but just didn’t see metalwork as the craft,” he acknowledged. “I also love finding new, good refer-
a viable career path, so I went to college for business,” he recalled. ence books for blacksmithing. I wanted to add to that library.”
Thomas had little enthusiasm for his work in the financial sector. “The Art & Craft of the Blacksmith” by Robert Thomas, 160 pp.,
“It was after I began tinkering in the garage on the weekends for is available from Quarry Books.
a while that I made the solid decision to move forward with seri- Learn more at www.quartoknows.com

28 I FORGING I MARCH/APRIL 2018

 Presenter of the
IndustryWeek
Best Plants
Award

May 8-10, 2018 | Raleigh Convention Center | Raleigh, NC

KEYNOTES: MEET THE TEAM BEHIND EAGLE PRIME

BILL RUH
CEO, GE Digital I SVP and Chief Digital Officer, GE • Panel and Q&A with
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• Plus, watch them judge

CHRIS MAPES
CEO and President I Lincoln Electric
the live robot talent show
Automation and Education: on the Expo floor
Addressing the Nation’s Skills Gaps

ROEL SCHOUWENBERG
Director of Intelligence & Research SEE FACILITIES IN ACTION WITH PLANT TOURS
Celsus Advisory Group
Cybersecurity for Manufacturers:
(Space is limited — first come, first served)
Is Your Operation Protected?

SEAN SUGGS
President
Toyota Motor Manufacturing Mississippi

MFGTECHSHOW.COM
REGISTER TODAY for the only event designed to keep manufacturing
decision-makers at the forefront of a fast evolving landscape in a digital era.
For additional questions, please contact florence.torres@informa.com.
 Te Metal
Makes the
Diference.

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Custom Melt.
Electralloy specialty alloys will help
you produce forgings that perform to • AOD ingots: 21"- 63"
the toughest standards. With longer • ESR/VAR ingots: 20"- 44"
life cycles, enhanced performance, • RCS from 4"- 36"
produc�vity and ul�mate reliability. • RDS from 3/4"- 36"
• Fully Condi�oned
THE METAL MAKES • Peeled/Polished
THE DIFFERENCE.
Choose from AOD, ESR or VAR. When your forgings have no room
www.electralloy.com
In ingot, remelted ingot, RCS billet, for error, get the metal that makes
round billet, peeled and polished bar. the difference. 800.458.7273