Explore how companies can avoid tariffs by sourcing their forging and metal requirements within their own country and the benefits this approach can offer. Companies often rely on international suppliers to source raw materials and components at competitive prices in today's globalized economy. However, fluctuations in trade policies and tariffs, such as those imposed during the Trump administration, have prompted many businesses to reassess their supply chains. One strategic move for companies looking to mitigate the tariff risks is shifting their focus toward procuring forging and metal products domestically.   Understanding the Tariff Situation   The imposition of tariffs on imported goods is one of the hallmark policies of the Trump administration, with the most significant tariffs targeting steel and aluminum imports. These tariffs aimed to boost domestic production by making foreign products more expensive. However, while the intention was to support U.S. manufacturers, many businesses, particularly in industries reliant on metal components, faced rising costs and supply chain disruptions. Tariffs can impact various stages of manufacturing, especially when companies depend on raw materials like steel, aluminum or other metals from foreign suppliers. The higher cost of imported goods due to tariffs can lead to price hikes, delays and potential strain on profit margins. Consequently, the question arises: How can companies avoid these tariffs and reduce their exposure to such trade restrictions?   Sourcing Metal and Forging Products Domestically The most straightforward way for companies to avoid tariffs is by procuring their metal and forging components from domestic suppliers. By sourcing materials from within their own country, businesses can sidestep the additional costs imposed by tariffs on imported goods. The U.S. has a robust metal forging industry, with many manufacturers offering seamless rolled rings, precision forgings and other metal products that are key to various sectors.   Opting for domestic suppliers not only mitigates tariff-related costs but also ensures that companies benefit from a closer, more reliable supply chain. Shorter transportation distances, faster lead times and fewer complexities in communication can make domestic procurement a more attractive option.   Supporting Local Economies and Building Relationships By procuring forging and metal products domestically, companies can contribute to the growth and sustainability of local economies. Supporting U.S.-based manufacturers helps to create jobs, stimulate economic development and foster innovation within the domestic market. In addition, it opens up opportunities for building long-term relationships with suppliers, which can lead to more favorable pricing, customized products and improved customer service.   When companies develop strong partnerships with local suppliers, they can work together to address specific needs, improve product quality and enhance the overall supply chain. This collaborative approach can result in cost savings, greater flexibility and a more resilient production process.   Quality Control and Regulatory Compliance Domestic suppliers are often more familiar with local regulatory standards, quality control measures and industry-specific requirements. This familiarity can simplify ensuring that products meet the specifications and certifications required for compliance with local laws and standards.   When sourcing internationally, businesses may face challenges in ensuring that their suppliers adhere to the same level of quality control and regulatory compliance. There may be language barriers, differences in manufacturing practices, and even logistical issues that could lead to quality discrepancies or delays. Companies can mitigate these risks by working with domestic forging and metal suppliers and maintaining better product quality and compliance oversight.   Reducing Supply Chain Risks Global supply chains are vulnerable to numerous risks, including political instability, natural disasters, pandemics and trade wars. During the first Trump administration, many companies saw their supply chains disrupted due to tariffs, particularly in industries reliant on imported metals and components. These disruptions could lead to production delays, increased costs, and, in some cases, a loss of business opportunities.   By sourcing materials domestically, companies can reduce their exposure to these risks. Domestic suppliers tend to be less affected by global trade tensions and external disruptions, providing greater stability and predictability in the supply chain. Additionally, by building a more localized supply chain, businesses can better control lead times and inventory levels, further reducing the chances of delays or shortages.   Flexibility and Responsiveness Domestic suppliers are generally more accessible and responsive when it comes to addressing urgent needs or making last-minute adjustments. Companies sourcing materials from international suppliers may face longer response times due to time zone differences, language barriers, and other logistical hurdles. With domestic suppliers, communication is often more straightforward, and businesses can more easily coordinate to meet changing demands or unforeseen challenges.   In fast-paced industries where time-to-market is critical, the ability to quickly adjust to changing circumstances can provide a significant competitive advantage. Working with domestic suppliers who can react swiftly to new orders, design changes or unexpected supply chain disruptions can help companies maintain a flexible and responsive manufacturing process.   Potential Cost Savings in the Long Term Although domestic materials may initially appear more expensive than those sourced internationally, the long-term savings associated with reducing reliance on tariffs and mitigating supply chain disruptions can be substantial. By avoiding tariffs and import-related costs, companies can preserve their profit margins while ensuring greater supply chain stability and reliability.   Moreover, domestic suppliers may offer more competitive pricing in the long run as companies build stronger partnerships and benefit from economies of scale. As the cost of raw materials fluctuates due to tariffs or other external factors, domestic suppliers can provide more consistent pricing and fewer surprises.   Conclusion Navigating tariffs and trade policies can be challenging for businesses, particularly those that rely on imported metal and forging products. However, by procuring materials domestically, companies can mitigate the risks associated with tariffs, reduce supply chain disruptions and support local economies. Beyond avoiding tariffs, domestic sourcing also provides improved quality control, greater flexibility and long-term cost savings.   In a time when supply chain stability is more important than ever, the move toward domestic sourcing of forging and metal products offers companies a strategic way to safeguard their operations and thrive in an increasingly uncertain global marketplace.

When selecting a forging process, understanding the differences between open-die and closed-die forging is crucial. Each method offers unique advantages that impact part geometry, strength and cost. This guide will help you determine the best forging solution for your needs. What is Open-Die Forging? Open-die forging, also known as free forging, involves shaping metal between multiple dies that do not completely enclose the material. The process allows for continuous deformation, producing strong, durable components with refined grain structure. Open-die forging is commonly used for large, customized components that require superior mechanical properties. Key Benefits of Open-Die Forging: Superior Strength & Durability:  Enhanced grain flow improves mechanical properties. Flexibility in Size & Shape:  Ideal for custom, oversized or unique components. Cost-Effective for Low Volumes:  Lower tooling costs make it economical for smaller production runs. Reduced Material Waste:  Efficient use of raw materials compared to machining from stock. Custom Alloy Selection:  Ability to use high-performance alloys tailored to specific applications. Best Applications for Open-Die Forging: Large industrial shafts and gears Heavy-duty aerospace and defense components Power generation equipment Pressure vessel components Large flanges and couplings What is Closed-Die Forging? Closed-die forging, or impression-die forging, involves shaping metal within a set of dies that fully enclose the workpiece. This method enables precise replication of intricate designs with minimal machining required after forging. Closed-die forging is preferred for high-volume production where consistency and efficiency are crucial. Key Benefits of Closed-Die Forging: High Precision & Repeatability:  Tight tolerances ensure consistent part quality. Enhanced Mechanical Properties:  Stronger and more fatigue-resistant than cast or machined parts. Cost Efficiency for Large Production Runs:  Higher upfront tooling costs are offset by lower per-unit costs at scale. Less Secondary Machining Required:  Near-net-shape forging reduces material waste and machining time. Superior Surface Finish:  Produces a clean surface with minimal defects. Best Applications for Closed-Die Forging: Automotive and heavy truck components Hand tools and industrial hardware Medical and surgical instruments Aerospace structural parts High-performance machine components Choosing the Right Forging Method Deciding between open-die and closed-die forging depends on several factors, including part size, complexity, production volume and budget. If you require large custom components with superior mechanical properties, open-die forging is ideal. If precision, repeatability and high-volume production are your priorities, closed-die forging is the better option. Additionally, consider factors such as lead time, material selection and cost efficiency. Open-die forging is advantageous when working with specialty alloys and when modifications may be necessary during production. Closed-die forging is preferable for mass production where every part must meet identical specifications. Key Differences Between Open-Die and Closed-Die Forging Feature Open-Die Forging Closed-Die Forging Precision Lower High Part Complexity Simple to moderately complex Highly complex Production Volume Low to medium Medium to high Strength & Durability Excellent Excellent Material Waste Minimal Reduced Tooling Costs Low High Need Expert Guidance? Our team of forging specialists is here to help you select the optimal process for your project. Contact us today to discuss your requirements and learn how our forging capabilities can enhance your manufacturing performance.

With Donald Trump returning to office, new policies and priorities are set to influence the trajectory of various sectors. From technology to energy, defense to mining, each industry faces unique circumstances that will define its growth. The Outlook for Major U.S. Industries in 2025 As we enter 2025, the economic landscape for major industries in the United States reflects a mix of challenges and opportunities shaped by innovation, policy changes and global dynamics. With Donald Trump returning to office, new policies and priorities are set to influence the trajectory of various sectors. From technology to energy, defense to mining, each industry faces unique circumstances that will define its growth. Below, we provide an overview of key trends and strategies for these industries under the Trump administration. Key Industry Insights for 2025 National Defense and Aerospace Geopolitical tensions and rising defense budgets are fueling growth in the aerospace and defense industries. Forgings are essential in the production of aircraft components, missile systems and other defense equipment, ensuring superior performance under extreme conditions. Modernization of defense systems, including advanced materials and cyber-resilient technologies, remains a priority. The commercial aerospace sector also anticipates recovery as global air travel rebounds, creating opportunities for innovation in fuel efficiency and safety. Trump's focus on strengthening national defense could further accelerate investments in these areas. Renewable Energy and Sustainability The renewable energy sector is expected to see significant developments, though priorities may shift under Trump's administration. Nuclear energy stands out as a critical component of the green transition, with forgings playing a key role in reactor pressure vessels, steam generators and containment structures. These components demand exceptional durability and quality to ensure safety and efficiency. As the U.S. seeks to expand its nuclear energy capacity, advancements in small modular reactors (SMRs) and next-generation technologies will increase demand for high-quality forgings. Policies may pivot toward energy independence, emphasizing nuclear and fossil fuels alongside renewables. Mining and Rare Mineral Collection The mining sector is experiencing renewed focus as the demand for rare earth minerals and critical metals intensifies. These materials are necessary for producing batteries, semiconductors and renewable energy infrastructure. Forgings play a vital role in mining operations, contributing to the production of drilling equipment, excavators and processing machinery that withstand extreme conditions. Trump's policies seem likely to favor domestic resource extraction, streamlining permitting processes and reducing environmental constraints to bolster supply chain security. Technology and Semiconductors The U.S. technology sector continues to lead global innovation, with semiconductors playing a pivotal role. Forgings are important in the production of semiconductor manufacturing equipment, providing high-strength, precise components that ensure durability and performance. Investments in domestic chip manufacturing, spurred by the CHIPS Act, aim to reduce reliance on overseas suppliers. Emerging technologies like AI, quantum computing and 5G are driving demand for advanced semiconductors, while sustainability concerns prompt a shift toward energy-efficient designs. With Trump's emphasis on reshoring and economic nationalism, domestic technology manufacturing is likely to receive additional support. 2025 Outlook with Trump in Office Policy Impacts on Industry Growth The Trump administration is expected to prioritize economic nationalism, deregulation and energy independence. Industries should prepare for shifts in trade policies , tax incentives and regulatory frameworks that could impact operational strategies and investment decisions. Strengthening Domestic Supply Chains Reshoring initiatives and investment in domestic manufacturing will likely gain momentum. Businesses must focus on supply chain resilience, leveraging federal incentives to enhance local production capabilities. Balancing Sustainability and Growth While Trump's administration may relax some environmental regulations, market and consumer demand for sustainability remains strong. Leading companies strive to balance economic growth with environmental responsibility, adopting energy-efficient technologies and practices where feasible. Finding the Right Partnership in 2025 In 2025, businesses across the U.S. will rely heavily on forging manufacturers to meet their operational needs. High-quality forgings safeguard critical components' performance, safety and durability, from semiconductor manufacturing equipment to mining machinery and defense systems. Companies must prioritize partnerships with suppliers who can deliver exceptional quality and reliability. Key factors to consider include: Precision and Quality: Confirm the forging partner has a proven track record of meeting rigorous industry standards. On-Time Delivery: Delays can disrupt entire supply chains. Choose a supplier with efficient production processes and robust logistics capabilities. Customization Capabilities: As industries evolve, bespoke forging solutions are often necessary to meet unique requirements. Technical Expertise: Look for partners who can provide guidance on materials, design and manufacturing processes. Forging partnerships with trusted suppliers will be critical for businesses aiming to maintain competitiveness and adapt to the dynamic demands of their industries in 2025. Conclusion While the outlook for major U.S. industries in 2025 under Trump's administration is marked by opportunities and complexities, forgings remain a cornerstone across sectors, enabling the production of critical components for technology, renewable energy, mining and defense. Like most businesses, Scot Forge will navigate the evolving landscape and drive growth by leveraging innovation, addressing workforce needs and adapting to new policies. It will emphasize a desire for strong partnerships, strategic foresight and adaptability to ensure success in a rapidly changing world. Ready to meet your 2025 goals? Contact us to discuss your project needs and learn how our forgings can support your nuclear energy goals. Contact us today!

IndustryWeek got wind of Scot Forge's partnerships with these large universities while looking for manufacturing employers who have successfully recruited millennials and reached out to Scot Forge. In recent years, Scot Forge has partnered with the Northern Illinois University (NIU) MBA program and the NIU undergraduate Business College’s Experiential Learning Center. We have worked with these student teams to discover solutions for current issues and to gain recommendations for moving forward. Scot Forge submits a problem statement, NIU interviews and selects the cross-functional team of students, and we communicate weekly throughout the semester until a plan is formulated. These projects are mutually beneficial... the students receive course credit while simultaneously gaining valuable real-world work experience, and Scot Forge gains actionable insights from some of the most precocious young minds in the nation. The students are also exposed to how a manufacturing facility operates, the various roles that are needed to run a successful company, and possible career opportunities in manufacturing. The career possibilities span from machinists and engineers, to accountants and metallurgists. In the past year, we have hired summer interns directly from these programs, some of whom are still employed today. Additionally, Scot Forge has partnered with the Kellogg School of Business - Executive MBA program, to discuss Marketing Branding and Marketing Strategy for Scot Forge. This partnership has tapped into the best and brightest throughout the country to help us innovate and grow. The students gain perspective into a 123 year-old American manufacturing operation and how we have continuously improved and modernized our technology to stay ahead in the market place and in front of competition. IndustryWeek got wind of these projects while looking for manufacturing employers who have successfully recruited millennials and reached out to Scot Forge. Read the Full Article

Scot Forge’s Tartan Bars feature a fully consolidated forged center, and a surface that is finished by multiple-pass rolling.Combining forging and rolling cuts press time in half; produces short runs in short order. By J. Neiland Pennington, Senior Editor - Modern Metals Scot Forge's Tartan Bars feature a fully consolidated forged center, and a surface that is finished by multiple-pass rolling. Combining forging and rolling cuts press time in half; produces short runs in short order. Until now, the cross section of forged round bars from Scot Forge have not been truly circular. They were actually polygons with as many as 50 sides, produced by multiple planishing strokes in the forging press. Now the Spring Grove, Illinois, company has introduced a forged bar that is round to one-half of the AISI tolerance for hot rolled bar. Trade named Tartan Bar, the material is produced in diameters of 6 to 16 1/4 in. and lengths from 8.8 to 30 ft. by a new automated bar mill that began production runs this February at Scot Forge's Clinton, Wisconsin, works. The bar mill completes a $ 14 million expansion begun three years ago. The project also includes two new plant bays totaling 50,000 sq. ft., nine tip-up heat treating furnaces, a 50,000-gallon tank for both water and polymer quenching, a 50,000-lb. capacity stacking crane, and a centerless bar peeler with a 4 in. through 16 1/4 in. diameter capacity. Manufacturing Tartan Bars combines conventional open-die forging with a roll planishing mill that Scot Forge says is unique in the bar industry. "This is not the same as hot-rolled bar," stated Dick Statton, Clinton vice president and plant manager. "It is forged bar with a fully consolidated center and a hot-rolled surface. Metallurgically, it is identical to a bar formed entirely by forging." Guaranteed sound center "Most conventional hot rolling mills won't guarantee a sound center in diameters above 10 to 12 in. We guarantee a sound center through 16 1/4 in." The technology is the result of efforts to reduce the forging press time required to planish a bar, and minimize press wear from the repeated pounding of planishing strokes. "Jim McKinley, our president, knew there must be a better surface finishing technique than forging 50 flats on a bar," said Sharon Haverstock, vice president of marketing. He had been at work developing a roll system of our own when he heard a presentation by GFM, GmbH, in Steyr, Austria, which developed the roll planishing mill. He was very excited about its capability, and brought the idea to our management group. Another intent of the roll planishing line is to free up forging press time. We have been working at full capacity, and our lead times have extended. We were looking for ways to improve both the product and the process. Forged preforms Producing Tartan Bars begins conventionally. Cast ingots are cogged into four-sided billets on one of two open die forging presses, then reheated and forged into 16-sided preforms. The process requires about half the press time of forging plus planishing on the forging press. A further shortening of the forging cycle is contemplated. "We may forge preforms into true octagons, rather than 16-sided double octagons, if we can maintain quality." Dick Statton said. "Our goal is to spend less and less time on the forging press." The preforms are transferred to the new bar line, which combines the roll planishing mill with a Braun abrasive saw and an Info-Sight programmable end marker. The runout table and multiple-stage cooling bed were built by Voest Alpine, which also integrated the line controls. The 1250-hp single-stand reversing planishing mill reduces the diameter of the bars by up to 12 percent. The rolling rate is 3 ft./second, and the rolls are automatically positioned for the required diameter, controlled by a computer that operates the entire line. The bars are typically rolled in 13 to 21 passes (always an odd number so the bar will exit downstream), depending on surface requirements. Rolling time for each bar averages about three minutes, and the production goal is 12 bars per hour. Automatic reversing cycle The automatic reversing cycle is initiated by entering the bar dimensions and alloy. The program selects the required number of passes, and closes the roll gap to progress from the starting to the finished diameter. Bar ends are trimmed by the automated abrasive saw, which spins a 5 ft. diameter glass fiber wheel coated with silicon carbide. A 16 1/4 in. diameter bar is trimmed in less than 30 seconds, and squareness of the end is comparable to bar stock cold-cut with a circular saw. Ends of the bars are imprinted with order and heat numbers by the automated dot matrix end stamper. Coding is currently entered manually, but will eventually be downloaded from the mill operations computer. The imprinted bars are transferred to a five-stage cooling table that rotates the bars to maintain straightness. The sixth station is an accumulator rack, and bars are removed by a 40,000-lb. capacity GCC (Gerlinger Carrier Co.) Straddle-Loader. Small quantities quickly Tartan Bars can be produced in smaller quantities with shorter lead times than hot-rolled bar, said Chris Scheiblhofer, planishing mill manager. "Hot-rolled bars are made in large runs and standard sizes by a series of roll stands that reduces the diameter more than our single-stand mill. Orders are necessarily large, and lead times can run two to four months." "The reversing mill gives us the ability to do with one stand at a lower cost what would normally require several stands, and the line automation allows us to make custom sizes. It is economically practical to purchase the production of only one ingot. Lead times are now from two to four weeks, and we are working on a guaranteed delivery program for Tartan Bars. Our goal is one week for untreated bars, and two weeks for heat-treated metal." Half-spec straightness Roundness is not the only Tartan Bar tolerance that is half the AISI specification for hot rolled bars. The standard straightness is also one-half the rolled bar specifications. One-eighth inch in any 5 ft. is standard, and 1/16 in. is available on special order. For hot rolled bar, the limits are 1/4 in. and 1/8 in. in any 5 ft. Tartan Bars are produced in all standard carbon and low-alloy steel grades, plus forgeable tool steels,and 300 and 400 series stainless steels. Both OEMs and service centers are seen as large potential markets. Sharon Haverstock believes that Tartan Bars will be of particular interest to service centers, given the combination of large size range, small minimum orders and rapid delivery. Rolling the surface of Tartan Bars generally lowers their cost, compared to conventionally forged steel. "If you are purchasing a bar made entirely in a forging press, you typically buy at least 1/2 in. of additional diameter to allow for machining," Haverstock advised. "Because the surface of Tartan Bars is smoother, you need less stock allowance, usually no more than 3/8 in. The net cost of the Tartan Bar will be less because you are buying fewer pounds of metal."

Massive, forged shock-absorbing dampers lend earthquake protection to Latin America's tallest tower. Scot Forge produced the parts to make it happen. Massive, forged shock-absorbing dampers lend earthquake protection to Latin America's tallest tower. Until recently, soaring skyscrapers and earthquake zones were considered mutually exclusive, but the use of revolutionary shock-absorbing dampers are now safely raising skylines in cities that are situated in fault zones. The new forged damper technology was employed to incorporate 17 additional stories into Mexico City's Torre Mayor Building while keeping the same load per square foot that it would have had with 38 stories, the former local building code limit for seismic protection. As a result, the 55-story Torre Mayor, meaning "Big Tower," is the tallest building in Latin America. A High Profile Project The Torre Mayor is a world class corporate complex and a premier Mexico City landmark, standing 738 feet tall. It is the ambitious development project of Paul Reichmann of Canada, with Canadian architects Ziedler Roberts Partnership providing an exquisite design that blends the light, airy feel of glass with a state-of-the-art tubular steel framework. It has 800,000 square feet of office space, as well as 32,000 square feet of commercial space housed within a two-level retail concourse that surrounds the lobby. Due to the tower's innovative dampers, provided by Taylor Devices (Buffalo, NY) with forged components supplied by Scot Forge (Spring Grove, IL), the tower represents an exception to the 38-story building code restriction that protects Southwestern Mexico's buildings from the area's volatile seismic activity. An earthquake measuring 8.1 on the Richter scale struck Mexico City in September 1985, and further quake activity occurred in 1999 due to the city's situation on top of the Cocos Plate, a highly active subduction thrust fault. "The 38-story code restriction was calculated to limit the amount of load per square inch that can be located safely upon this fault zone and its soft, sand-based soil," says Taylor Devices' president, Doug Taylor. "So, Torre Mayor project engineers approached us with the question: can the building be taller than 38 stories if we use dampers to lighten the load per square inch? A programming analysis showed the answer was yes. Consequently, with the Torre Mayor's seismic loads dramatically reduced by the dampers, the tower meets the load-per-square-inch restriction even with 17 extra stories." In fact, the dampers from Taylor Devices, who develops products for seismic protection in partnership with the headquarters for U.S. seismic research at the State University of New York at Buffalo, ensured structural reliability for the tower in earthquakes measuring up to 8.5. The Dampers that are Making the Difference To understand damper technology, "think of the shock absorbers in your car," says Taylor. "A damper is a very large shock absorber with a cylinder-and-piston design, in which the piston forces oil through orifices to exert force. Now, here's the main difference between the shocks in your car and a damper in a building: a car's shock absorber exerts 400 pounds of force, while each damper in the Torre Mayor building exerts well over a million pounds of force." He notes that the Torre Mayor damper design evolved from a product formerly used in military applications to protect missile launch sites against nuclear attacks. In architectural applications, the dampers can be built into the steel bracing. The Torre Mayor design incorporates 24 dampers within the bracing on each of the building's two long walls, mounted with hidden bolts. It is the first tall building to use mega brace damping elements, where a single damper spans multiple floors. The dampers are plainly visible through the windows. The 24 large dampers are 6' long x 24" O.D., with a 16" bore, and are rated at 1,260,000 lbs. damping force each, while 74 smaller dampers used in the short walls of the structure are rated at 600,000 lbs. High Strength Construction The dampers for the Torre Mayor were constructed using the open die forging process. Open die forging is ideally suited for damper production because of the large dimensional requirements of the cylinders, as well as the ability to forge the inside diameter around a pin, rather than drilling it out. By forging a hollow rather than drilling out a solid cylinder, considerable material savings were realized. Scot Forge placed a hot ring preform over a mandrel pin, then elongated the workpiece to form the cylinder. Forged end caps were later threaded onto the end of each cylinder to close the bore. The forging process also provides superior strength due to continuous directional grain flow-i.e., steel grains are deliberately oriented in a direction that improves mechanical properties and metallurgical soundness. Forging provides unmatched structural strength and integrity, because internal voids and porosity are eliminated as cylinder walls are consolidated during the forging process. The pistons also benefit from the extra strength and integrity provided by forging. Taylor sought a reliable forging supplier for the Torre Mayor project, stressing that "it's important to choose an experienced forging company with the right equipment, and one that takes responsibility for their work." Taylor turned to Scot Forge after a previous forging supplier's product cracked, due to a failure to ensure uniform cooling. "Scot Forge has the know-how and the machinery to produce high performance forgings efficiently," Taylor says. Scot Forge produced a total of 504 components to make up the 96 dampers. These components included rough machined cylinders, cylinder caps, cap nuts, mounting flanges, and piston heads. All were forged from 4140 normalized, quenched and tempered steel. The pistons were produced using Scot Forge's unique Tartan BarÒ process. In the process, the round bars that would become pistons were initially forged to produce sound centers for internal structural integrity. Each bar was then rolled to a smooth surface in under five minutes, in the company's state-of-the-art bar planishing mill. The process allowed the bars to be produced efficiently, while providing the improved soundness, integrity, and high strength that is required of the pistons when in service and under high stress. Recent Quake On January 21, 2003, the coastal region of the State of Colima, Mexico experienced a 7.6 magnitude earthquake. When the quake reached Mexico City it was amplified by the soft soils in the area. This resulted in a relatively strong response with some 30 seconds of shaking. At the time of the quake, thirty-one floors of the recently opened Torre Mayor were occupied, the balance still undergoing final interior finishing. An occupant reported that he saw hanging light fixtures beginning to sway and heard a slight noise, then turned toward the noise and saw that the large damper outside his office was stroking. This, of course, signified that an earthquake was occurring. Occupants also reported that from inside the building the quake felt far less severe. This may well be due to the extensive use of fluid dampers as a primary element of the building's seismic protection and earthquake resistance capability. A Government required post-earthquake inspection was performed with no damage of any kind noted. The Torre Mayor has received several American Construction Industry awards and was one of the four finalists for the U.S. Civil Engineer Research Foundation's 2003 Charles J. Pankow Award for Innovation. Conclusion Forged dampers are poised to improve the future of building in earthquake zones. In addition to their incorporation into the Torre Mayor Building, they are appearing in other high profile earthquake-zone projects including the San Francisco Bay Bridge. And forged dampers helped keep the new Seattle Mariners stadium intact during the 6.7-magnitude quake that hit in February 2001- more proof that the art of earthquake protection has reached a new level.

An 8-ton forged master cylinder, with a forged piston and end caps, helped relocate the historic Cape Hatteras Lighthouse. The cylinder was used in the largest U.S.-built jack to save the 208-foot beacon — the world's tallest brick lighthouse — from an eroding shore. Three unique forgings were instrumental in granting North Carolina's storied Cape Hatteras Lighthouse a reprieve from the encroaching Atlantic Ocean. The components are part of a colossal jacking system used in a $12 million relocation project that lifted the lighthouse from its original foundation on the Outer Banks, moved it over a half mile and lowered it onto its new location. The lighthouse was built in 1870 on Hatteras Island, near Buxton, to warn mariners of menacing Diamond Shoals. Its site was 1600 ft. from the open ocean, a distance that the builders believed would make the lighthouse invulnerable. In the ensuing 129 years, however, beach erosion has advanced the sea almost to the base of the light. The National Park Service, which oversees the Cape Hatteras National Seashore, had two alternatives: Move the structure to safety or let it succumb to the advancing surf. In an era when large-vessel navigators rely on global positioning satellites, the Cape Hatteras Lighthouse represents maritime history worth preserving. And for craft not equipped with GPS, it is still a potential lifesaver. At 208 ft., the Cape Hatteras Lighthouse is the tallest brick structure of its kind in the United States, a fragile 4800-ton masonry spire with aging mortar joints. Moving the lighthouse required lifting and rolling while maintaining it absolutely plumb. Tilting could at the least result in massive cracking. At worst, the lighthouse could be reduced to a pile of historic rubble. Jahns Structure Jacking Systems (JSJS) has confronted similar problems before. The Elburn, Illinois company manufactures specialized equipment for lifting and moving structures, and has previous experience in lighthouse relocation: Rhode Island's much lower Block Island light in 1993.

CTI Molecular Imaging (Knoxville, TN), in a joint effort with Scot Forge recently converting a cast component to a forging in the production of steel rings and hubs for its Eclipse Cyclotrons. The growing diversity of medical diagnostic systems and related equipment has led to an increasing demand for forged parts in the medical industry, such as large rings and hubs for MRI scanners, PET scanners, cyclotrons, and other equipment. Application requirements call for these parts to be of the highest quality, while budgets continue to call for cost-efficient production. CTI Molecular Imaging (Knoxville, TN), in a joint effort with Scot Forge recently met both of these requirements by converting a cast component to a forging in the production of steel rings and hubs for its Eclipse Cyclotrons. CTI is the leading provider of positron emission tomography (PET) scanners and cyclotrons. Established in 1983, the company has won numerous awards for its advances in molecular imaging. CTI provides total solutions for the PET industry with its integrated line of scanners, cyclotrons, molecular probes, detector materials, and support services-all aimed at helping physicians diagnose diseases earlier and more accurately than with traditional imaging technologies. A cyclotron is essentially a particle accelerator for the production of F-18, the radioactive biomarker that is injected into patients undergoing PET scans for early cancer detection. A main component of a cyclotron is a steel ring, providing a circular arena wherein proton particles are accelerated at high speed to generate an 11 meV proton beam essential for the production of F-18. Each 57" OD x 47" ID, 12" thick ring is plated with nickel and copper to convey RF energy as well as to optimize the high vacuum environment needed for proper system operation. Two steel hubs, 57" OD, 17" long, also help provide a vacuum sealed environment. The rings and hubs comprise the flux path for the electromagnet and must have a tightly controlled carbon content. Until recently, the metal rings and hubs in CTI cyclotrons were cast, but problems with porosity in the castings were causing expensive rework during the machining and plating. Andy Williamson, Mechanical Design Manager for CTI, elaborates. "The surface finish was often too porous for the plating to seal properly without special rework," he says. Also, pinholes in the surface invited unwanted contaminants. Bringing the cast rings up to specification involved "excessive filling of holes and welding," Williamson says. "Rework was necessary during both the machining and plating operations, causing cost issues and delays. We needed another solution." Looking to replace the casting with an alternative metalworking process, CTI did extensive research into using forgings. Forging is becoming an increasingly desirable alternative to casting in the production of large medical components. The forging process, regardless of section size, guarantees internal soundness, whereas the internal structures of cast parts weaken in larger-sized parts, resulting in porosity. And with advancements in forging technologies and methods, forged parts are now available in a variety of shapes-rivaling cast part shapes-at less cost than in the past. CTI quoted the parts from several forging companies, which reinforced these findings. Williamson says, "we concluded that the overall cost of a forged and machined part with plating would be 10 percent less expensive than what we were paying for a cast, machined and plated part." Comparative Analysis When compared to castings open die and rolled ring forged metal parts deliver: Directional grain flow and superior final part strength Structural integrity and product reliability Reduced process control and inspection requirements More predictable response to heat treating CTI chose Scot Forge, of Spring Grove, Illinois, to supply the forged parts after Williamson and Purchasing Manger Juel Hensley visited Scot Forge's plant. "Scot Forge had by far the best capability to produce the rings and hubs," Williamson says. The 100-year-old ISO 9001:2000 certified forging company uses thousands of tools, torch cutting, sawing, machining, and presses that are custom-designed by their own engineers to produce uniquely shaped, repeatable parts at competitive prices. Tom Schwingbeck, Jr., Director of Technical Sales and Services at Scot Forge, states that "our forging expertise, extensive capabilities, and proactive approach with CTI to understand their requirements and expectations, helped to cost effectively convert castings to forgings while supplying a superior product". Scot Forge produced each Eclipse Cyclotron ring to near net shape by forging a wrought billet into a rough donut on a 1,250 ton hydraulic press, then rolling the part on a Wagner ring mill to create a seamless rolled ring with highly desirable mechanical properties and metallurgical soundness. Porosity is prevented through this forging process because, in the forging of a heated cast ingot, the ingot is consolidated, providing a sound center component. The coarse grain cast structure is broken up and replaced by a fine grain wrought structure providing a sound center product with excellent structural integrity. Following the forging and rolling process, each ring is rough machined at Scot Forge to 57-1/2" OD, 46-3/4" ID and 12-1/4" thick. The hubs are forged to near net shape on a 3,000 ton hydraulic press, then rough machined to 59" OD x 10-3/4" long, stepped down to 40-1/2" OD x 9-7/8" long. Finally, the rings and hubs are normalized to ensure a uniform microstructure with high dimensional stability for finish machining. Another important specification met by Scot Forge was the low carbon material required for the ring and hubs. "In order to keep the cyclotron magnet power low, the steel needs good magnetic permeability, so it must have a very low carbon chemistry," notes Williamson. The CTI specification called for a steel with a carbon content not above .10%. "Scot Forge's metallurgical engineers worked with us to meet this specification," Williamson says. "In fact, they exceeded the spec, giving us a specially formulated 1008 (.08-.10 carbon) material." CTI has now tested the forged ring and hub prototypes with excellent results, and the parts have been qualified. Plating has been applied to the finish machined surface with no sealing problems. Based on these results, CTI recently placed eight production orders with Scot Forge. "Just six years ago, we didn't consider forgings because castings were less expensive and could accommodate more configuration features," says Williamson. Now, companies like Scot Forge are offering more complex forged parts than ever before available, at lower overall production cost. Consequently, CTI will be using forged rings and hubs in all of its future cyclotrons.

Forgings support Seattle Mariners' new ballpark roof. Forged gear pinions, bull gear rings, wheels axle pins, and connecting pins provide the strength needed to support the outdoor park's 11,000-ton retractable roof. As Seattle Mariners fans look out over a bright green natural-grass playing field in the city's new outdoor ballpark next July, some may be inclined to ask, "Is this heaven?" Indeed, the completion of the park will be the fulfillment of a dream for many--from the team's owners and designers, contractors, and even the fans. Most expect attendance levels to increase over the characterless indoor Kingdome's. The park's open-air design evokes the nostalgia of more traditional ballparks, and has views of the Seattle skyline. Nonetheless, players and fans won't be left out in the rain--thanks to a moving roof that extends over the stadium when showers threaten, then retracts when it clears. Blacksmith measures a finished ring A computer-controlled, steel wheels-and-rails roof-moving mechanism opens and closes the roof with the push of a button. "It's like putting the top down on a car, and as easy to use as a garage-door opener," says Neil Skogland, president of Ederer Incorporated, the Seattle-based crane company responsible for making the roof extend and retract. Although the roof is intended to cover, not seal, the stadium, the design must stand up to tough conditions. The high-strength wheel axles, gear pinions, and connecting pins that anchor the roof trusses to the wheeled trucks must stand up to 70-mph winds, earthquakes with lateral-ground accelerations of up to one-third the force of gravity, and six-ft snow drifts. That's why Ederer selected open-die forging for these critical components. Other critical components include 96 10-hp dc motors from Baldor, dc drives and PLCs from Allen Bradley Co., and gearboxes from Sumitomo Machinery Corp. Sound forged centers According to Ederer Project Manager Steve Hertel, the sheer weight of the roof, combined with just moderate winds, makes for high loads. But worst-case scenario, the design load exceeds 300,000 lb per wheel. "That's why cold-rolled steel, used in typical wheel-and-rail systems, didn't meet our strength requirements," Hertel explains. "Castings and fabrications, that are subject to internal defects, don't provide the sound-part centers that result from open-die forging. The process really has an edge over other metalworking processes in terms of directional, structural, and impact strength." Finding a manufacturer to deliver in the required lead time at a competitive cost was a challenge because of the sheer volume of large parts, 432 in all. "One of the larger connecting pins alone weighs 5,000 lb.," notes Hertel. After comparing quotes from forge shops around the world, Ederer awarded the contract to Scot Forge (Spring Grove, IL) based on its ability to meet the demand and its cost-effective approach. "We have a long-standing relationship with Scot Forge and know them to be reliable," Hertel adds. In addition to meeting demand, Scot Forge provided unique solutions for minimizing costs. The pinions that drive the wheel bull gears are integral to the gearbox output shaft. The parts are typically produced by machining a larger-diameter forging to create the step for the pinion. "At a count of 96, this approach would have been wasteful in terms of material usage. And machining costs would have been high. By working the step into the product during the forging process instead, we cut costs significantly," says Hertel. One of a kind Only one other retractable roof exists in the U.S., the Arizona Diamondbacks' Bank One Ballpark in Phoenix. The Diamondbacks' roof uses a cable-drawn system, not designed for the more volatile weather conditions of Seattle. The Seattle Mariners' roof weighs 11,000 tons, with the roof-moving equipment bringing the total weight to 13,000 tons. Yet while most people would consider the roof heavy, Hertel points out that each roof section catches the wind like a sail. The tricky part for Ederer was engineering a system with high wheel loads and large lateral loads due to the wind and seismic forces that the roof must withstand. The Roof The roof must stand up to 70-mph winds, earthquakes with lateral-ground accelerations of up to one-third the force of gravity, and six-ft snow drifts. Ederer's roof-moving concept won a design competition sponsored by the ballpark's Seattle-based architects NBBJ, and structural engineers Skilling Ward Magnusson Barkshire, to generate solutions. Expertise gained as principle vendor to NASA for rocket and Space Shuttle handling cranes helped Ederer win the bid. To make the three roof sections glide over the ballpark, 16 wheeled assemblies support the roof sections. Eight wheeled assemblies roll along each of two 816-ft rails, mounted to the stadium's north and south sides. Each wheeled assembly, or truck, uses eight wheels and weighs 130,000 lb. One wheel alone weighs a ton. Sensors ensure that each side moves at the same speed, and a computer controls the 96 10-hp motors that power the trucks. The roof is over 600 feet wide, and moves at approximately six inches per second-about the speed of a leisurely stroll. "It takes about 20 minutes to completely open or close the roof," notes Skogland. Ederer specified AISI 4340 steel, heat treated to 311/352 BHN. The grade's alloying elements (nickel, chromium, and molybdenum) deliver the desired mechanical properties throughout the entire cross section. "Through-hardening, especially important in the gears, allows them to transmit high torque and to have long life," Hertel states. Wheeled trucks The roof uses open-die forged parts including: 96 bull gears; 96 step shafts linking the gears to the wheels; and 240 wheel-axle and connecting pins that anchor the roof trusses to the wheeled trucks. On schedule Scot Forge Account Specialist Jason Artner runs down a list of parts the firm has delivered: 96 forged rings to be cut into bull gears, 96 forged pinion shafts linking the gears to the gearboxes, and 240 forged bars to be used as wheel axles and as pins connecting the truck assemblies to the roof trusses. The 5.75-inch-thick rings used for the gears have a 36.75-inch OD and a 9-inch ID. The 51.75-inch-long pinion shafts have 3.03-inch diameters, with a 6.75-inch step in diameter. Spindles The bars, or pins, range in length from 31.625 to 69.5 inches, and the diameters range from 9 to 18 inches. Artner explains, "The wheeled assemblies connect to the roof trusses using a series of horizontal sills secured by the forged pins. The pins connect the lowermost sills up to intermediate sills and top sills. Each sill, and the pins that connect them, get progressively larger with altitude. Sixteen upper connecting pins each have an 18-inch diameter and are 69.5 inches long. Weighing 2.5 tons each, they carry over 2,500,000 lb. vertical load. Forged pins also make up the axles for the 128 wheels on the eight trucks. Considering the enormous loads riding on the pins, it's important that they have sound forged centers." With the ballpark scheduled for completion in July 1999, the three roof sections should be completed by the end of the year. "Scot Forge is helping us to meet that deadline," Hertel asserts. Ederer delivered all components for the first section of the roof in May and the second section in August. As of this writing, the rest of the components are finish machined, assembled and stored, and ready for delivery. The Mariners' new stadium is truly a "field of dreams," allowing fans to enjoy a game under clear skies. But for all who participated in the roof's construction, the realization of the dream occurs when they are comfortably watching the game from the stands on a rainy day, with the roof rolled securely in place overhead.

Scot Forge worked with Deca Industries to create a highly unusual three-spoke forging. The forging replaced a casting used in the mining industry. Forging readily accommodates a wide variety of shapes while simultaneously imparting exceptional strength. But when it came to a highly unusual rotor arm fashioned in a three-spoke configuration, no one was sure whether it could be done. Deca Industries Ltd., Saskatoon, Saskatechewan, Canada, is a 40-person industrial job shop that repairs heavy mining equipment. Founded in 1977, Deca specializes in serving the potash and the uranium mining industries. This unique application arose when Deca's customer, International Mining Corp. (IMC), wanted to fix a disabled rotor arm integral to the operation of a continuous boring mining machine. As the machine cuts through potash, the rotor arm holds the tools that actually make the cuts. Deca engineers determined that the part couldn't be repaired; rather, it had to be replaced. This was no small decision since the rotor arm is 90 in. in diameter, 4 ft thick, with three telescoping arms and a total weight of 7,000 lb. Deca began exploring fabrication options for the replacement part. Since the existing component had been a casting, Deca looked again at that method as well as machining and open die forging alternatives. "Acknowledging all the forging advantages, a question still remained," said Francis Nagy, Deca's president. "Could this part actually be manufactured as an open die forging? As far as we knew, the rotor arm's unusual shape wouldn't normally lend itself to forging." Yet Deca was intrigued. To investigate further, Deca turned to Scot Forge, its Spring Grove, IL, supplier of forged spindles and rings. Several steps were needed to produce the rotor arm. Nagy took the part's original blueprints and casting drawings down to Scot Forge where manufacturing details were worked out jointly. The new part started as a pancake-shaped piece of 4140 alloy base stock that was then formed into a seamless rolled ring via the open die forging process. Three torch-cut sectors were then drawn out and forged into journals. Once the forged part was finished, it was sent to Deca for secondary processing. "This was an enormous undertaking," Nagy said, "from the sheer standpoints of size and shape. We were amazed with the results." When IMC received the part, it passed the quality inspection. The new rotor arm has been in the field for two years now and has performed to everyone's expectations.

SpaceDev (Poway, CA) and Scot Forge worked together to make the dream of private space flight a reality, moving quickly from drawing board to launching pad. On June 21, 2004, in the famous words of Neil Armstrong, another "giant leap" for mankind took place 328,491 feet above the California desert, as pilot Mike Melvill became the first civilian to fly a craft beyond the Earth's atmosphere. The historic launch of SpaceShipOne - the first privately funded craft to successfully reach space - is significant because it opens the doors to private space flight and commercialization. It also represents the first new rocket engine developed for human space flight since 1972. California-based SpaceDev, contracted by the aerospace development company Scaled Composites, was responsible for the design and manufacture of the solid fuel grain and other major components of the propulsion system. The launch required a craft constructed of the most dependable and durable materials. When these demands - as well as the project's compressed timeframe - became evident, SpaceDev enlisted the forging expertise of Scot Forge. The Right Stuff Some of the components SpaceDev provided for SpaceShipOne's rocket motor, included the igniter, injector and main operating valve. Their design for SpaceShipOne's hybrid propulsion system called for a bulkhead for each solid booster rocket - five in total - that would not only contain and feed the propellant, but also separate and protect it from the motorcase. "This main oxidizer bulkhead design is what led us to the forging process and, ultimately, Scot Forge," explains Jeff Hickerson, SpaceDev's Mechanical Engineer - Hybrid Propulsion. "Forging brought all the advantages this design required high-strength, structural integrity and the elimination of porosity." More so than any other available metalworking process, forging provided the consistent material strength necessary for this application. Through forging, the metal is heated and mechanically formed between dies under controlled conditions. In addition to producing the desired shape and dimensions, the forging process also dramatically increases the strength of the material. Structural strength is increased by the elimination of the cast structure, enhanced density and improved homogeneity. The directional strength is improved by aligning the grain flow in specific directions. Meeting the Deadline with Quality Once forging was agreed upon, SpaceDev began searching for the right partner for the job. Beyond the quality requirements, this forging provider needed to be able to work with the specified high strength stainless steel (15-5 PH VAR material), and deliver the final product within a 6-week timeframe. The challenge was met by Scot Forge. "Scot Forge offered exactly what we were looking for in terms of quality and material requirements," Hickerson said. "And most critically, they were able to deliver on time." Headquartered in Illinois, Scot Forge is an open die and rolled ring forging company, and their wide range of experience, including military and aerospace applications, provided an advantage for this project. "Because of our metallurgical expertise," said Tom Schwingbeck, Jr., Dir. of Technical Sales and Services for Scot Forge, "we were familiar with the material, and knew how to forge it to SpaceDev's specifications." Within the 6-week deadline, Scot Forge delivered five forged blanks, each with an O.D. of 24 3/8". The forging process ensured a lack of voids in the material, which was a chief concern for SpaceDev. "The little cavities - voids - that often appear in cast metals were too much of a performance risk for us," said Hickerson. "We chose a strong stainless steel, with good natural properties. The forging process helped maintain and bolster the strength and consistency of the steel." After being forged, the blanks were solution treated, age hardened and then rough machined. Additionally, Scot Forge performed ultrasonic testing to meet the MIL-STD-2154 Class A standards required for the bulkheads. "Forging was definitely the right process for the specific and unique demands of this application, and played a role in the success of the mission" said Schwingbeck. "Scot Forge is very proud to have been a part of this historic flight." Making History and Forging Ahead The collaboration of SpaceDev and Scot Forge was instrumental in helping the dream of private space flight move quickly from drawing board to launching pad. The groundbreaking flight on June 21, 2004 was the culmination of years of research, preparation, design, and testing. The success of this maiden flight led to two additional launches on September 29 and October 4, which captured the coveted Ansari X-Prize: a ten million-dollar award for consecutive private extra-atmosphere launches. "The possibilities for this type of flight, and the capabilities of this craft have been demonstrated," said Hickerson, whose group is working on other larger, low cost propulsion systems and further innovation. "The doors are definitely open now. Who knows what the future holds?"

History was made at 12:31am Monday, August 5th, 2012 on the fourth planet in this solar system as NASA’s Mars Science Laboratory rover Curiosity descended to a picture-perfect rocket-guided and slowed descent to a gentle, wheels-first, sky crane touchdown on the surface of the Red Planet. History was made at 12:31am Monday, August 5th, 2012 on the fourth planet in this solar system as NASA’s Mars Science Laboratory rover Curiosity descended to a picture-perfect rocket-guided and slowed descent to a gentle, wheels-first, sky crane touchdown on the surface of the Red Planet. Scot Forge manufactured the rover wheels and backshell plate that are both critical components and crucial to the success of this mission. The forgings were ordered by NASA’s Jet Propulsion Laboratory. Putting the boots on Curiosity may have been a once-in-a lifetime opportunity, but the icing on the cake came when the first image returned from Mars was a black and white photo of a Scot Forge made wheel! The objectives of the Curiosity rover include investigating the possibility of life on Mars (its habitability), studying its climate and geology, and collecting data for any future manned mission to Mars. The rover carries a variety of scientific instruments designed by an international team. The Jet Propulsion Laboratory has many sources for forgings, but ultimately Scot Forge was selected for NASA’s grandest of missions. The technology and engineering behind this program are nothing short of mind-boggling. No other country in the world has landed a rover on another planet, and the “sky crane” landing borders on Science Fiction. Truly, we have helped accomplish one of humanity’s greatest feats, and for that we should all be very proud.