Main Entry: 1forge
Pronunciation: 'fOrj, 'forj
Etymology: Middle English, from Old French, from Latin fabrica, from fabr-,
Date: 13th century
1 : a furnace or a shop with its furnace where metal is heated and
wrought : SMITHY
2 : a workshop where wrought iron is produced or where iron is
Main Entry: 2forge
Inflected Form(s): forged; forg·ing
Date: 14th century
1 a : to form (as metal) by heating and hammering b :
to form (metal) by a mechanical or hydraulic press with or without heat
2 : to form or bring into being especially by an expenditure of
effort <working to forge party unity>
1 : to work at a forge
- forge·abil·i·ty /"fOr-j&-'bi-l&-tE, "for-/
- forge·able /'fOr-j&-b&l, 'for-/ adjective
Main Entry: drop-forge
Pronunciation: 'dräp-"fOrj, -"forj
Function: transitive verb
: to forge between dies by means of a drop hammer or punch press
- drop forger noun
Definitions used by permission from the publisher. Merriam-Webster's
Collegiate® Dictionary ©2000 at Merriam-Webster OnLine, www.Merriam-Webster.com
Depiction of an early European forge works.
Forgings - Manufacturing Cycle
Shultz Steel Company's raw materials are primarily vacuum arc remelted
steels, titanium alloys and nickel base alloys. Conventionally melted and
cast aluminum ingot is also used.
In 1996, Shultz Steel installed its own Vacuum Arc Remelting (VAR) facility
for the remelting of steel and nickel alloy ingots. This new facility
requires the procurement of cast electrodes melted in an electric arc furnace or
vacuum induction furnace. Subsequent VAR melting at Shultz Steel converts
these electrodes into Aerospace quality ingots. Ingots are cylindrical in
nature (from 20 to 40 inches diameter), weighing from 10,000 lbs.(titanium and
aluminum) up to 40,000 lbs. (steel).
These ingots are initially heated and open die forged in three or four
operations to a billet product. This billet product is subsequently
examined and inspected to verify its eternal and internal quality.
The billet material is subsequently saw cut into specific weights ("Mults")
for the manufacture of open or closed die forgings. This process consists
of heating the material two to six times and progressively changing its shape by
forging until it finally is molded to the contour required by the drawing.
Following final forging, the product normally is heat treated to develop the
internal properties in the metal. It is subsequently cleaned, using
abrasive materials and chemicals to remove the outer surface layers.
Following this, most products are partially machined and then inspected
thoroughly for dimensional and metallurgical characteristics. The final
product is shipped to the customer at this point.
An Ingot is upset forged in open dies under pressure into a flattened shape
("slab"). A hole is punched into the slab to permit the next
operation, ring rolling. The slab is heated to forging temperature and
placed over the internal roll of the rolling machine. At the same time,
pressure is applied to the wall by the external roll as the ring rotates.
This process produces a circular forging with a seamless cross-section.
The rings are then rough machined to a rectangular cross-section.
Aluminum rings are cold sized (tension stress relieved) to reduce built up
residual stresses. Rings are then heat treated and undergo a final rough
machining, parting and inspections and tests prior to shipment. The
customer then must fashion the part from the rectangular shape to suit his or
her own specifications and needs.
Shultz Steel employs a full machine shop, with product ranges from simple
drilling of datum targets, all the way to finished detail parts and assemblies.
Closed die forgings are typically rough machined at Shultz Steel, to permit
easier set-up at the customer facility. Some alloys require rough
machining to reduce the cross sectional thickness in order to permit adequate
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