With the right material selection, proven forging processes, and proper tools, Weldaloy has all the ingredients to manufacture seamless rolled rings in less time, with less material wastage, and with a more uniform grain that ensures the strength and reliability of your product.
The goal of this technical paper is to help you determine which forging process is right for you in meeting your seamless rolled ring needs. Because when you fully understand the differences between each forging process, you can improve your design and, ultimately, the quality and performance of your product.
Weldaloy offers complete forging capabilities to a variety of industries such as aerospace, power generation, electronics and others using copper, aluminum, and other non-ferrous forgings. We manufacture seamless rolled rings using the open die forging process, closed die forging process, and rolled ring forging process.
Seamless Rolled Ring Forging Process
With our 40-ton ring rolling machine, Weldaloy has the capability to manufacture seamless rolled rings using most of the metals we offer. This process provides significant flexibility allowing for various sizes, and provides a more uniform product that is stronger, more reliable and made in less time and with less material waste than traditional forging processes.
The process starts with raw material (a blank) being cut to size, then rounded to a disk shape.
The blank is punched then pierced in the center, using the open die forging process, to create a preform in the shape of a donut.
The donut shaped preform is then placed on the ring rolling mill for rolling.
The axial rollers control the height of the ring. The idler roller, or mandrel, applies pressure to the preform by pressing it against the drive roller to decrease wall thickness and height and increase ring diameter until the correct diameter is reached.
Whether your order is 10 rings or 100 rings or more, the seamless rolled ring forging process minimizes the variation from ring-to-ring.
Forged rolled rings can be configured in various sizes as shown in the table below. Specialized orders can be produced to manufacture seamless forged rolled rings in customized configurations.
Open Die Forging Process
In the open die forging process, a piece of metal is deformed by placing it between dies that do not completely enclose it. The dies hammer or deform the metal through a series of movements to achieve the desired shape and form. From here, the product can be sent on for heat treatment and machining to achieve the tolerances and specifications for the finished product.
Rings that have special mechanical requirements or that may require warm work or cold work, or are too large to be produced on a ring rolling mill can be open die forged.
Closed Die Forging Process
This process is best suited for producing rings that are smaller in size and in higher quantities and do not have difficult mechanical property requirements.
The Weldaloy Advantage is Clear
Weldaloy’s Vertical Integration Process provides significant advantages in meeting your seamless rolled ring forging needs:
Weldaloy has the equipment and forging processes to accommodate a wide range of sizes to meet your ring needs. Below is a summary of each process. We also have the expertise to help you with custom and/or unique product orders.