Forging

Forging is the process of shaping steel into desired form through plastic deformation under pressure at high temperatures (850–1200°C). Large cross-sections, special shapes, and parts requiring high mechanical properties that cannot be produced by rolling are manufactured through forging. The minimum forging ratio is 3:1, which completely closes porosity and segregation in the cast internal structure.

In open die forging, steel is shaped by being compressed between flat or profiled dies. With a 1700-ton hydraulic press, forged bars in the diameter range of 140–1000 mm and lengths up to 12 meters are produced. The workpiece is rotated at each step with a manipulator arm to ensure homogeneous deformation.

Closed die forging is performed with pneumatic hammers. Parts between 1–150 kg are forged in pre-prepared dies to near-final shape. This method is preferred especially for serial production parts (flanges, valve bodies, gear blanks). Material waste is minimized through net-shape or near-net-shape production.

Controlled cooling is applied after forging. Depending on steel grade, slow cooling in furnace (alloy steels) or air cooling (carbon steels) is preferred. Each forged part undergoes internal structure inspection through ultrasonic testing and is evaluated according to EN 10228-3 or SEP 1921 standards.