Forging

Shultz Steel uses the latest technologies to support our commitment to quality. Our 40,000-ton, all-forged, press is the largest forging press installed in the United States in over 50 years. Shultz is the pioneering forging company in the use of computer modeling to design forging dies and processes.

Our fully equipped CAD stations allow us to work with dimensionless drawings to design forging shapes and build forging dies. Our integrated manufacturing system uses electronic data to control machining and inspections, and provides us with the capability to send data electronically to our customers.

40,000 Ton Press

This 5.2 million lb press can forge components with up to 40,000 tons of pressure. The plan view area is 5,000 square inches. For closed die operations, part weight can range from 10 to 13,000 pounds.

6,000 Ton Press

This press can apply up to 6,000 tons of pressure to convert ingots into billet stock. This piece of equipment is integrated with a 35 metric ton rail-bound manipulator. For open die operations, weight can be as high as 50,000 pounds. Maximum length is 40 feet. Maximum width is 70 inches. Sleeves can measure up to 120 inches.

28,000 Ton Press

This press can extrude (fine grained) powdered Super Alloys into billets. Back extrusions up to 63 inches long can be accommodated. The maximum outside diameter is 60 inches. Forward extrusions can measure up to 35 feet, and have an outside diameter up to 22 inches.

1,500 Ton Press

Open die operations on a variety of shapes can be accommodated on this press.

Vertical Drop Quench Furnace

This furnace enables less than 15 second quenching of aluminum rings up to 268 inches in diameter.

5,000 Ton Ring Sizer

For large seamless rings up to 312 inches in outside diameter, the ring sizer provides tension stress relief.

• Maximum weight is 20,000 pounds.
• Maximum face height is 72 inches.

After 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.