METALLURGY DEPARTMENT
Overview of Metal Forming
Processes
Sand Direct/Primary
Forming Forging
Casting Processes
Rolling
Investment
Casting Extruding
Indirect/Second
ary Forming Drawing
Powder Processes
Metallurgy
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METALLURGY DEPARTMENT
Forging Process Review
There are three
main forging
methods
1 2 3
Open die forging Closed die
forging Ring forging
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METALLURGY DEPARTMENT
1. Open Die Forging
Forging is done at temperatures in excess of
1,000C. Note color of billet.
Forging presses can range from 1,000T to
50,000+ T
There is no restraint on the flow of the
material after pressed.
8,000T Press
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METALLURGY DEPARTMENT
Transformation of the Cast Structure to a
Wrought Forged Structure
Forging will close off porosity and
stretch out any segregation.
Note the
presence of
porosity &
segregation
in the ingot.
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METALLURGY DEPARTMENT
Forging Effect on grains
Heat
softens
Forging Reduction Ratio
Forging Press
the bar
Cross
and allows sectional area ingot
hammer to
deform
= normally ≥ 3:1 Notice the
bar. grain flow
Cross sectional area
after forging
Cast Ingot
Press reduces the
diameter of the bar in
excess of 3:1
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METALLURGY DEPARTMENT
Examples of Oil & Gas Open Die Forgings
Spool body forging
BOP forging
Larger size
Spool body forging components
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METALLURGY DEPARTMENT
Onlybar
Forged problem
used to is that
make it isCameron
many only
Products
pressed in the rolling direction
Forging is only in
the rolling Advantages
Guideline
direction recommendations
1. Forged or rolled bar is
1. Only use forgedavailable.
commercially bar when
the design allows for pre-
Charpy Impact
Properties 2. heat
Forged
treatismachining
cheaper than
and
affected, presence
a [Link] No
a good bore.
queue
particularly
large diameters time and not necessary
2. Some designs
to use may need
large presses.
to be produced from a
3. forging
Bar canto be
achieve the to
machined
desirable properties.
the pre-heat treat
dimensions & heat
treated.
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METALLURGY DEPARTMENT
2. Closed Die Forging
Direction of
Movement
Hot Metal Billet being Material flows to fill mold
Billet squeezed shape
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METALLURGY DEPARTMENT
Examples of Closed Die Forgings
Finished
choke
valve
Choke valve body
Gate valve body
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METALLURGY DEPARTMENT
3. Ring Rolling Process
1 2 3
4 5
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METALLURGY DEPARTMENT
Example of use in Connectors FORGING
2 types: CHC and CVC
connectors
MACHINING
• Connection systems are used to
enable pressure tight connections
between subsea production
systems.
• Items such as flow lines, SLITTING
umbilicals, manifolds & trees.
• fluid is allowed to travel thru the
connection.
• Uses a series of 4⁰ tapered COLLET SEGMENT
segments to provide primary
locking mechanism.
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METALLURGY DEPARTMENT
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METALLURGY DEPARTMENT
Sample Locations
T
¼T
T
4” 8”
4”
8” 8”
10”
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METALLURGY DEPARTMENT
Forgings: Mechanical Properties
T
Why do tensile & Test Requirements@1/4T
charpy in two
directions? • Transverse tensile
• Transverse Charpy
• Longitudinal tensile
• Longitudinal charpy
¼T
T
4” 8”
4”
8” 8”
10”
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METALLURGY DEPARTMENT
Review of a Forging Certification
MS Material
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METALLURGY DEPARTMENT
Example of Test Locations from Drawings
The gauge length of the
tensile bar must be
outside of the heat
treat buffer
Heat treat cover
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METALLURGY DEPARTMENT
Example of 1st article data from a MAME Tree
Spool Forging
Start with the 3X sacrificial sections
prolongation
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METALLURGY DEPARTMENT
MAME Tree Spool Forging- Prolongation
Mid-section1 2
Sacrificial
(KSI) (KSI) Sacrificial
Forging Prolongation
section 2 data NQT & SRSacrificial section 1
(21.87"
(11" wall
wallthickness)
thickness) (7.5" wall thickness)
Yield Yield
Yield (KSI)
95
95 100
9197 96
96 96
90
89 95
90
90 89
88 94
88 93
93
86
90
85
85
tt
fafcac
thtehel & &
85 && a a tetded l
io nosns uduidninepeopror
i
80
80 ct atat gigt it e er r
Minimum
fa 75Ksi requirement lolcoch hlolnon nsnisl il
t he l & e d No
t et
No t b
e o ot tete
t
s & d i na po r t a a t beresrese
on u e 80 h h
t t nsnvsv
c ati ngit ile r trtara
e lo h lo n s
e
Minimum 75Ksi requirement
t t t
75
75 No t bo rse
t ha n s v e
tra 75
70
70
70
65
65
65
60
60
B-1-1/4
B-1-1/4 ; ; ; ; ; 60 ;
B-1-1/4 ; ; ;
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METALLURGY DEPARTMENT
Example Closed Die Forging
Sacrificial
Sacrificial
section 1
section 3
Sacrificial
section 2
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