Forgings
Open die forging is the process of shaping any hot metal parts. This is done with a top die that is attached to a ram and the bottom die gets attached to a hammer or bolster. Metal parts need to have appropriate temperatures, somewhere in the range of 500°F to 2400°F. These can then be shaped into the desired configuration with the help of skillful hammering or even by applying pressure to the workpiece. Sometimes, open die forging is also referred to as free forging or impression die forging. The metal is constantly hammered and stamped to finally achieve a certain set of dimensions within the open die forging process.
The process requires continuous movement of work piece to achieve the desired shape that requires complex mechanical controls and skilled operators.
Advantages of open die forging
Reduce chances of voids
Improve fatigue resistance
Provides continued grain flow
Greater strength and improved microstructure
Any complex shapes can be producedForged rolled rings
Ring rolling forgings is a process used to manufacture rolled rings with the help of rolling mills. The seamless ring rolling forging is produced on an automatic 4000 MT hydraulic press to form a hollow “donut”. These rings can be produced in various configurations ranging from flat washer-like parts to tall and cylindrical shapes. The diameter of the manufactured rings can range from a few inches to more than 300 inches with max weight of 10,000 lbs
Flanges and blinds
Standard Flanges (Weld-neck, Slip-on, Socket-weld, Lap-joint, Blind and Screwed Types) are manufactured to specifications of ASME B16.5, ASME B16.47, ASME B16.48, BS EN 1092, BS 4504, API-605, API-590, MSSSP44, DIN 2632 to 2638, DIN 2576, 2642, 2527, 2566. Flanges cover a full range of pressure ratings of these specifications (150 – 2500 psi for ASME & PN6-PN400 for DIN / EN flanges). As the best flange manufacturer, the non-standard flanges are made up to a diameter of 180 inches and the weight not exceeding 10,000 lbs
Self reinforced nozzles and hollow
Self reinforced nozzles (SR Nozzles) with plain end as well as with complex profiling in fully machined condition for Pressure Vessels designed to ANSI, ASME codes in all steel grades. Nozzles, hollow forgings and self reinforced nozzles are offered, in carbon steel, alloy steel, stainless steel and duplex steel up to 100 inches diameter.
Forged blocks and flat plate
- We have the capability to manufacture forged block and flats.
- Width : 12 – 72 inches
- Thickness : 6 – 24 inches
- Length : 40 - 240 inches
- Maximum forged weight : 50,000 lbs
Forged shafts and stepped shafts
We offer wide range of forged shafts and stepped shafts such as rotor shafts, turbine shafts, generator shafts, custom forged shapes etc. Below are our capabilities.
- Minimum outer diameter : 8 inches.
- Maximum outer diameter : 64 inches
- Minimum length : 32 inches
- Maximum length : 240 inches can be scaled up to 800 inches
- Maximum forged weight : 50,000 lbs
Capabilities
We are committed to provide quality products for delivering superior performance by gaining competitive advantage.
Heat treated forgings are manufactured with precision to induce strength and optimize mechanical properties. One of our strengths purely stands on recording products manufactured in the ERP using Digital Vernier’s having Wi-Fi connectivity.
Some of the equipment that turn around the engineering team to deliver are:-
- Heat treatment furnaces electrically and gas operated
- Charging and material handling equipment
- Mobile manipulators for indoor & outdoor application
- New Open Die Forging Hydraulic Press
- CNC Machines for various applications
Key equipment
- 4000T fully automatic oil hydraulic press
- 3800 MT Automatic Hydraulic Open Die Forging Press
- Hydraulic hammers for open forgings
- Mobile forging manipulators
- Mobile charging machines
- Ring parting machine
- CNC machines for various applications
- 30MT Rail bound manipulator
Furnaces
Forging
- Electrically operated re-heating furnace
- Gas operated re-heating furnaces
Heat Treatment
- Electrically operated drop bottom furnace
- Gas operated furnace
Certifications
- Quality Management System as per EN ISO 9001: 2015 By TUV NORD
- ISO 14001:2015 By TUV NORD
- OHSAS 18001:2007 by TUV NORD
- AD 2000-Merkblatt W0 By TUV NORD