Forgings are essential in advancing cancer treatment machines, contributing to the precision, reliability and safety of these critical medical devices. Forgings in Cancer Treatment Machines: Enhancing Precision and Reliability in Medical Equipment In the realm of medical technology, precision and reliability are paramount, especially when it comes to cancer treatment machines. Behind the scenes, the choice of materials and manufacturing processes plays a vital role in the performance of these life-saving devices. So, let’s take a look at the significance of forgings in cancer treatment machines and how these components contribute to the advancement of medical technology. Forgings in the Medical Industry: Forgings have found extensive applications in various industries due to their inherent strength, durability and ability to maintain tight tolerances. In the medical field, where precision is non-negotiable, forgings have proven to be instrumental in the production of critical components for cancer treatment machines. Key Components Utilizing Forgings in Cancer Treatment Machines: Linear Accelerator Components: Linear accelerators are fundamental in radiation therapy for cancer treatment. The components of these accelerators, such as gantry structures, target positioning systems and collimators, often involve forgings. The high strength and precision of forgings contribute to the stability and accuracy required in delivering targeted radiation doses. Support Structures: Forgings are commonly used to construct support structures for medical equipment. These structures provide the necessary stability for the intricate movements and adjustments required during cancer treatment procedures. Patient Positioning Systems: Precision in patient positioning is critical for cancer treatment success. Forgings are utilized in manufacturing components within patient positioning systems to ensure accurate and repeatable positioning during radiation therapy sessions. High-Stress Components: Certain components within cancer treatment machines, subjected to high stress and demanding conditions, benefit from the enhanced mechanical properties of forgings. This includes parts that experience repeated movements and exposure to radiation. Advantages of Forgings in Cancer Treatment Machines: Strength and Durability: Forgings exhibit exceptional strength and durability, ensuring that components withstand the rigorous demands of cancer treatment machines over extended periods. Dimensional Accuracy: The precision achievable through the forging process is crucial for maintaining tight tolerances in components, contributing to the overall accuracy and reliability of cancer treatment machines. Reduced Material Waste: Forging minimizes material wastage compared to other manufacturing processes, aligning with sustainability goals in the medical industry. Quality Standards and Safety: Components used in cancer treatment machines must adhere to stringent quality standards and safety regulations. Forgings, often produced to exact specifications, contribute to the overall reliability and safety of medical equipment, meeting the rigorous requirements of the healthcare sector. Forgings are essential in advancing cancer treatment machines, contributing to the precision, reliability and safety of these critical medical devices. As technology continues to evolve, the use of forgings in the healthcare industry exemplifies the synergy between material science and medical engineering, ultimately enhancing the capabilities of cancer treatment machines for the benefit of patients worldwide.    Image Source

Strengthening the manufacturing sector and revitalizing domestic production capabilities through quality employment opportunities that can be obtained with a high school diploma. Since the pandemic, a renewed focus has been on strengthening the manufacturing sector and revitalizing domestic production capabilities. The manufacturing industry provides quality job opportunities that can be obtained with a high school diploma. This article sheds light on the significance of manufacturing jobs, specifically focusing on forging, machine repair, maintenance technicians, heat treat operators and non-destructive testing (NDT) inspectors. Scot Forge offers many of these opportunities, so we will explore the importance of these occupations, their impact on the economy and the skills and qualifications required to excel in these fields. Forging: Crafting the Backbone of Manufacturing Forging is a fundamental process in the manufacturing industry, providing various components with the necessary strength and durability. Skilled forging specialists create intricate shapes and designs using heat and pressure, transforming raw materials into critical components for many industries, including aerospace , defense , infrastructure and energy industries. The forging sector requires skilled workers who can operate heavy machinery, interpret technical drawings and adhere to stringent quality control standards. Machine Repair and Maintenance Technicians: The Guardians of Production Machine repair and maintenance technicians are essential in keeping manufacturing operations running smoothly. These professionals possess various technical skills and expertise, ensuring that machinery and equipment function optimally. They diagnose and troubleshoot mechanical issues, perform routine maintenance and conduct repairs when necessary. The demand for skilled machine repair and maintenance technicians continues to rise as manufacturing processes become more advanced and automated. Heat Treat Operators: Enhancing Properties of Parts Heat treat operators play a vital role in the manufacturing industry by applying controlled heat treatments to enhance the strength, durability and other desired properties of materials used in various products. By carefully manipulating the heating and cooling cycles, heat treat operators can influence material hardness, tensile strength, ductility and other mechanical properties. This level of control is crucial in industries such as aerospace, construction, oil and gas, national defense and energy, where the reliability and safety of the end products are paramount. NDT Inspectors: Safeguarding Quality and Safety Non-destructive testing (NDT) inspectors are responsible for assessing manufactured products' integrity, reliability and safety. By employing various testing methods—such as ultrasonic, radiographic, magnetic particle and liquid penetrant inspections—NDT inspectors identify potential defects or flaws without damaging the product. Their meticulous inspections ensure that components and materials meet industry standards and specifications, crucial in maintaining quality and safety across multiple sectors, including power generation , manufacturing, semiconductor and aerospace. US manufacturing jobs are important for the country's economic well-being. They contribute to industrial growth, innovation and the creation of high-quality products. The value of these occupations has become even more evident as the United States seeks to strengthen its manufacturing base and ensure self-reliance in critical industries. To succeed in these fields, individuals need a combination of technical skills, problem-solving abilities and a commitment to maintaining high standards. As the manufacturing landscape continues to evolve with technological advancements, these occupations will remain in demand, offering promising career paths and opportunities for individuals to contribute to the nation's manufacturing prowess. By investing in education, training and professional development, the United States can further support its manufacturing workforce and maintain its position as a global manufacturing leader. Scot Forge offers these career paths plus many more, with the added bonus of a built-in retirement plan known as an Employee Stock Ownership Plan (ESOP). Read more about our ESOP here and learn about current position openings here !

Semi-cap must withstand extreme conditions and perform accurately and reasonably, which is where forgings come in. Forgings are a critical component in manufacturing semiconductor capital equipment (semi-cap), which includes the machinery, tools, and equipment used to produce semiconductors. The semi-cap industry relies on forgings for high-quality components that are required to meet strict standards of reliability and durability. Semiconductors are used in various electronic devices, from smartphones and laptops to medical equipment and military systems. The production of semiconductors involves complex processes that require precise control of temperature, pressure, and other variables. Therefore, the semi-cap equipment used in this process must withstand extreme conditions and perform accurately and reasonably, which is where forgings come in. Why Forgings for Semi-Cap Equipment? For many semi-cap components, forgings provide superior strength, fatigue resistance and reliability. They are made by heating a metal billet to a specific temperature and pressing or hammering it into the desired shape. This process creates a denser, stronger and more uniform component than other manufacturing methods, such as casting or welding. One of the main advantages of forgings is their strength because the forging process creates a more uniform grain structure in the metal. This leads to a component that is less likely to crack or fail under high stress or pressure. Another advantage of forgings is their fatigue resistance. When a metal component is subject to repeated stress, it can eventually fail due to fatigue. Forged components are less susceptible to fatigue failure because the forging process compresses the metal, making it more resistant to cracks and other forms of damage. What Semi-Cap Components Use Forgings? In addition to their strength and fatigue resistance, forgings are highly customizable. The forging process can create components in a wide range of shapes and sizes with varying degrees of complexity, making forgings ideal for the semi-cap industry requiring precise dimensions and performance characteristics. Some of the most common semi-cap components made using forgings include chambers, frames, brackets and other parts subject to high stress and harsh operating conditions. These components are critical to the operation of semi-cap equipment and must be able to perform with high accuracy and consistency. Chambers are a key component in semi-cap equipment because they are used to create a controlled environment for the manufacturing of semiconductors. Forged chambers are preferred because they can withstand high temperatures and pressure without deforming or cracking. This is critical because any deformation in the chamber can result in defects in the semiconductor, impacting its performance and reliability. Frames and brackets are also essential components in semi-cap equipment because they provide support for other parts and help maintain the equipment's alignment and stability. In addition, forged frames and brackets are optimal because they can withstand high stress and shock during production processes. In addition to these components, forgings are also used to make various other parts in semi-cap equipment, including flanges, fittings, valves, and fasteners. These components must withstand the high pressure and corrosive environment of the semiconductor production process, making forgings an ideal choice. In summary, forgings play a critical role in the semi-cap industry by providing high-quality components required to meet the strict standards of reliability and durability. The strength, fatigue resistance, and customizability of forgings make them ideal for semi-cap components that must perform under harsh operating conditions. From chambers to frames and brackets, forgings are a crucial component in manufacturing semi-cap equipment. Scot Forge provides semi-cap components in ferrous and non-ferrous materials; call us today to discuss your forging needs!

In a manufacturing setting, employee-owned means aligning the interests of employees with those of the company and its customers as the employees participate in an Employee Stock Ownership Program (ESOP) At Scot Forge, we are proud to be an employee-owned company, but what does that mean for our customers? In a manufacturing setting, employee-owned means aligning the interests of employees with those of the company and its customers as the employees participate in an Employee Stock Ownership Program (ESOP). An ESOP is a type of retirement plan that allows employees to purchase or hold stock in the company and plays an important role in customer relationships as employees have a vested interest in their company's and its customers' success. One of the key benefits of an ESOP is that it creates a sense of ownership and investment among employees. When employees have a stake in their company, they are more likely to be invested in its success and take an active role in driving it. This can lead to increased employee motivation and engagement, which can translate into better customer service and higher-quality products. The sense of ownership also fosters continuous improvement both internally and externally as our owners look for ways to create value for our customers.  An ESOP can also help build trust and loyalty between employees and customers. When our customers know that the employees they interact with are invested in the success of their company, they are more likely to trust and value the relationship. This can be especially important in a manufacturing setting, where customer relationships are often built on the quality of products and the level of service provided. Employee retention can also be positively impacted in an ESOP company, and personnel continuity is important for maintaining customer relationships and quality products. Especially in today's job environment, employees who feel invested in their company and are motivated to contribute and share in its success, they are less likely to leave. This can help to ensure continuity of service and consistent quality for customers. Furthermore, an ESOP can also help to improve employee productivity and efficiency, which can lead to cost savings. When employees are invested in their company and motivated to work hard, they are more likely to be productive, efficient and look for ways to add value. This can translate savings for the customer in material, the time it takes to complete downstream processes, and even the ware and depreciation on machines. Moreover, ESOPs foster a culture of employee collaboration and teamwork, which can benefit customer relationships. When employees work toward a common goal and have a sense of shared ownership in their company, they are more likely to work together and communicate effectively. As a result, customers experience better communication leading to improved problem-solving, quicker decision making and the opportunity for innovation, which benefits both companies and their end users. Finally, an ESOP can also be a powerful tool for attracting and retaining top talent. When potential employees see that a company offers an ESOP, they may be more likely to be attracted to the company and view it as a long-term career opportunity with the potential for a healthy retirement. This can attract and retain high-quality employees.

When bridge owners must select a process and supplier to produce a critical metal component, they face an enormous array of possible alternatives. Many metalworking processes are available, each offering a unique set of capabilities, costs and advantages. When bridge owners must select a process and supplier to produce a critical metal component, they face an enormous array of possible alternatives. Many metalworking processes are available, each offering a unique set of capabilities, costs and advantages. The forging process is ideally suited to many part applications. In fact, forging is often the optimum process for both part quality and cost, especially for applications that require maximum part strength, custom sizes or critical performance specifications. So why did so many engineers choose castings over forgings at the peak of bridge construction (c. 1960)?  Unfortunately, most federal bridge safety standards were not created until the late 1960s in response to the Ohio River bridge collapse. The failure was caused by the bridge's corrosion and decay, which weakened it to the point of collapse, killing 46 people. After analysis, it was discovered that a microscopic crack formed in a steel eye bar used in the bridge's construction during the casting process. Over time stress and corrosion fatigue caused the crack to grow until the component failed. Today, it is well known that castings lack the continuous grain flow, refined grain structure and directional strength necessary for critical, load-bearing operations. The lack of properly oriented grain flow and refinement can lead to potential part integrity problems causing failures in the field. In the1960s, hundreds of casting foundries in the U.S. could supply the complex or large metal components required for bridgework. In addition, castings were cheap and plentiful compared to steel forgings at that time. As demand for steel castings outpaced supply, however, companies began to look outside of the U.S. and Canada for solutions, which ultimately impacted the supply chain in two ways:  1) It gave birth to an offshore option for steel castings which reached its height and inflicted significant damage on the domestic industry in the following decades. 2) OEMs were not content back then to wait for the offshore option to develop fully, so casting users moved aggressively to invest in a substitute process – steel fabrication. In fact, the presence of fab shops within virtually every manufacturing plant – which we take for granted today – did not exist before the late 1970s and is the direct result of those mentioned above.  The North American steel foundry industry is a shadow of its former self. In 2015, fewer than 200 steel casting plants remained, down from a 1970s high of more than five times that many. Today's more demanding material users are increasingly obliged by everyday economic and competitive realities to seek a better supply-chain solution and stronger, sounder and technically superior product. However, when deciding on bridge construction and repair, the question still is … "casting, fabrication or forging?" BEARING HOUSINGS  Manufacturing components with a welded plate or welded ends produce quality issues from inconsistencies in using different metalworking processes. Inclusions are common, and welded parts often require extensive weld repair and re-inspection. By making the component a single forged piece with integral flanges, quality is improved throughout the part, eliminating instances of inclusion and removing the welding time altogether. The strength and structural integrity of the forged material meets demanding application requirements, resulting in less rework, fewer rejections and increased part life. Additionally, eliminating welding shortens part production process time, and the component is better able to withstand the rigors of field use. PINIONS, FLOATING SHAFTS, TRUNNIONS  Machining a solid bar to form a pinion, floating shaft, or trunnion causes wasteful use of material, labor and time. Inclusions are common on the machined surface, which may cause product rejections and result in excessive time and costs spent repairing the part. Additionally, grain flow within the bar is exposed when machined, thus making the material more susceptible to fatigue failure due to exposed grain ends. On the other hand, custom forging requires less starting material than a straight round bar machined to shape. Material cleanliness is optimized by controlling melt practices and teaming processes, eliminating material rejections due to inclusions. Less machining saves money, time and tool life while producing a closer-to-finish shape. Lastly, a forged stepdown contoured grain flow yields greater impact and directional strength. ANCHORAGE BARS AND LINKS/GUDGEON ASSEMBLIES  This product is often made from a cast head welded to a hot rolled bar. Due to the lack of uniform grain structure within castings, this product often proves too weak for the intended application, resulting in shortened product life. Cracking is typical in the weld layer, causing failures in the field. Additionally, welding the two pieces together is time-consuming. The excessive heating required during the welding process changes the hardness and tensile properties in the weld zone, making it necessary to re-heat treat the part. Fortunately, this product can be manufactured as a single-piece forging instead, improving properties and eliminating non-value-added steps. The elimination of welding provides dimensional stability, reduces the amount of inspection and simplifies inventory management. Most importantly, the strength and structural integrity of the forged material meets demanding application requirements, resulting in less rework, fewer rejections and increased part life. CONSIDERATIONS  If you are looking for a new approach to repairing infrastructure, there are many factors to consider when converting a historic design. Often, securing engineering's approval is the key to making enhancements. When reviewing your component, it is helpful to take a step back and ask, "What is the purpose of my design?" The best results occur if you're willing to think creatively and challenge traditional methods.  If you are considering forgings, you should partner with a supplier willing to work with your engineers to educate them about conversions, forgings and the newly expanded range of product types (complex parts) that can be produced as a forging. Rather than dismissing the idea as impractical or impossible, consider the technical and/or economic merits of any particular conversion project.

With the growing momentum behind offshore wind vessels, how can shipyards and machine shops ready themselves for the assumed influx of demand? Earlier this summer, the U.S. Department of Transportation’s (DOT’s) Maritime Administration (MARAD) announced the designation of offshore wind vessels as Vessels of National Interest. This designation is meant to spur more offshore wind construction and bring additional focus to project applications for review and funding through the Title XI Federal Ship Financing Program (Title XI). The Title XI program assists the domestic shipbuilding industry by providing financial support for U.S. shipyards to modernize facilities, build and retrofit vessels and help U.S. shipowners purchase new domestically-produced vessels. “We’re excited that some American shipyards have already secured contracts to build vessels to service offshore wind developments,” said Maritime Administrator Ann Phillips. “By growing [the shipbuilding industry], we further support essential offshore wind installations and continue to add jobs and strengthen our important domestic industrial base, including our shipyards and shipbuilding industry.” This assistance program and the Vessels of National Interest designation, recently made available for offshore wind vessels, are significant milestones to help the U.S. reach 30 gigawatts (G.W.) of offshore wind by 2030, the initiative set in motion by the President. Currently, more than 58 different types of vessels are needed to make offshore wind arrays possible. Dominion Energy, a major player in offshore wind, is the first to invest in a U.S.-flagged offshore Wind Tower Installation Vessel (WTIV) in Brownsville, Texas, that will be operational by late 2023. Not far behind are Orsted and Eversource, energy companies that have contracted with Edison Chouest in Louisiana to build the first U.S.-flagged Service Operations Vessel (SOV). In addition, Great Lakes Dredge & Dock is developing the first U.S.-flagged offshore wind Fallpipe Vessel for subsea rock installation as early as the first quarter of 2024. These three vessels are essential for the industry to meet current deployment goals, with additional vessels needed for different stages of offshore wind tower implementation. The vessels needed for the early stages of development help with surveying to place buoys, map the seabed, take seafloor samples, prep the seabed and ensure project safety. These include: Geotechnical Survey, Jack-Up Vessel Geophysical Survey Vessel Scout Vessels Dredge Vessels Next, for wind tower installation, the vessels needed to prep the foundation, transfer turbine components and personnel, lay cabling and provide noise mitigation are: Crew Transfer Vessels (CTV) Wind Tower Installation Vessels (WTIV) Service Operation Vessels (SOV) Jack-Up Barges/ Vessels U-Feeder Vessels/ Feeder Barges Noise Mitigation Vessels With all this growing momentum behind offshore wind vessels, how can shipyards and machine shops ready themselves for the assumed influx of demand? Most shipbuilders feel the biggest challenge in supplying vessels for offshore wind is not capacity but engineering and procurement. Design engineers often fail to provide a completed design upfront, augmenting ship design after, just before or during the building, drastically impacting delivery lead times. Furthermore, procurement of parts, especially now, as resources continue to be constrained due to overseas tensions, seems to pose a threat. This is why asking the right questions upfront and establishing strong U.S. manufacturing partnerships are critical. While Scot Forge can’t speak to the processes of design engineers, we can say we know the importance of a fully integrated American supply chain. From steel production, forging and ABS inspection to heat treatment, NDT and semi-machined parts ready for fabrication, we only use U.S.-sourced labor and material. That said, shipyards and shipbuilders often don’t specify a vendor for forgings or castings. They leave that selection to the machine shops they partner with to produce the ready-to-install component. So, whether you are a shipyard project manager or need to procure near-net-shaped metal parts, the U.S. has a supply chain ready to support your needs. Scot Forge has the experience, material and ABS relationships required to provide the parts that will set your vessels sailing. From a single ABS Grade 2 bar to pinions that support a jack-up rig, our owners have decades of experience delivering the quality required to build a vessel.

Finding the right forging method for your metals requires knowing your options. Here is the complete guide on open die forging vs. closed die forging. As of 2022, the global metal market is worth  around $3,949 billion.  This makes sense considering the number of applications metal has in our daily lives. Metal is a staple of our existence, from movable bridges to aluminum space equipment to consumer electronics. Open die vs. closed die forging are two metal forming options for those who want to have custom metal parts manufactured. Here, we will discuss these two metal forming processes and how they impact grain flow and utility. Read on to learn which approach best meets your needs. What Is Open Die Forging? Open die forging is a metal forming process that uses multiple dies. None of these dies completely enclose the material as the component is being shaped. Instead, the dies hammer the metal over and over until the forger creates the desired end shape. Before the process begins, the metal is heated in a furnace. This makes it malleable so that dies can alter its shape. Hammering and pressing the metal lets you achieve any shape. Assuming that the expert making the material understands metalworking, they will know exactly how to change the billet's dimensions without needing to fully enclose the metal. Open dies are simpler than closed dies because they do not require a specific shape to contain and shape the metal. Open Die Grain Flow, Benefits and Downsides The grain flow structure is one of the most significant open die forging benefits. As the metal is worked into the desired shape, grain flow is strengthened as it follows the contour of the piece. The grain flow movement is possible because force is applied to the metal during various forging operations, including upsetting, drawing out and/or rolling. These methods of forging create a final product that is not porous. In fact, the final product will be stronger and more durable due to its even grain flow and improved microstructure. Some other open die forging benefits include: Continuous grain flow and finer grain size Consolidation of voids in the material Greater fatigue resistance for long-term use Eliminates shrinkage and similar defects Less material waste (eco-friendly) Better production scheduling as different parts can run through the shop at the same time   There are also a few disadvantages: Usually requires some machining to create the correct dimensions The inability to create shapes with intricate inner passages Rough surface finish (unless refined later)   Open die forging is the most conventional metal forging process available. As a result, despite its shortcomings, it is ideal for R&D, prototypes, oversized components or small-run applications. How Is Closed Die Forging Different? Closed die forging is a slightly different process than open die alternatives. It is not a free forging process. Instead, it is often called "impression die forging" because it uses a die impression to give the metal its shape. Like open die forging, the metal for closed die is heated in a medium frequency induction  heating furnace . However, it is then placed in an enclosed die molded in the desired shape of the final product. Then, the metal is compressed and formed into the end product through high pressure or multiple hammer impacts. Molding dies are made with precision machines before a metal preform is placed between the top and bottom dies. Depending on the component type, machining might not be needed after the end product is removed from the die. This is because the closed die process creates intricate components depending on the detail of the dies. Closed Die Advantages and Disadvantages Like open die forging, internal grain flow is formed since material reduction is involved in creating the product. There are some things closed die forging excels at: A cost-efficiencies are realized with this method for large production runs Little machining is required in most cases (for close tolerances) The ability to create tighter tolerances   Still, other areas are lacking compared to open die forging. These downsides include: High costs are associated with the manufacturing of the dies making this process too expensive for short production runs (since the die production costs are high) The time to produce the dies can push out your deadline Constrained capacity in closed die shops (Once a run is booked, they are locked into that one part until production is complete)   Ultimately, certain applications require closed die forging methods. However, it is less conventional than open die methods. Which Metal Forging Process Should You Choose? Open die forging is generally used for products manufactured in small quantities, require large sizes, and are critical for the end user or R&D. Generally, open die forging shapes are easy and used for more straightforward shaped products (rather than complex ones). Some examples of products made from open die forging include: Small discs Forged and rolled rings Forged cylinders Domes Rollers Forged shafts Metal sleeves   These products are often used in shipbuilding, mining, defense and energy industries. However, they are also used in the machines that manufacture semiconductors, food/beverage equipment, industrial machinery, paper and more. Furthermore, with a skilled Forge Development team, like the one at Scot Forge, many complex shapes can be manufactured through the open die forging methods. On the flip side, the closed-die forging process is generally reserved for creating smaller and more complex products and large production runs. Some items made by closed die forging techniques include: Forged fittings Lifting hardware Rigging hardware Small/precise car parts Valves   Because of the precision level, closed die forging is essential in industries like commercial aircraft and automotive markets. In general, forgings keep users safe from part malfunction due to the contoured grain flow resulting in higher strength components. Get Started With Metal Forming Today While finding the perfect metal piece for your applications can be challenging, it doesn't need to be. Custom forging services can give you tailored parts that meet your precise specifications. Scot Forge is committed to creating components you can rely on from quality to delivery.  Request a quote  to learn if forgings fit your project's needs and the best method of manufacture available to you.

The additive manufacturing process is just the inverse of subtractive manufacturing, where the material is removed from a single piece of material using milling, cutting or turning; it is the method of adding or joining materials together using heat, pressure or magnetism/electricity. One clear thought probably comes to mind – 3D printing. From aerospace applications to medical devices in materials ranging from plastic to metals, 3D printing is swooping into manufacturing as an option for making highly complex parts that need to be strong and lightweight. The additive manufacturing process is just the inverse of subtractive manufacturing, where the material is removed from a single piece of material using milling, cutting or turning; it is the method of adding or joining materials together using heat, pressure or magnetism/electricity. From that perspective, there are many different approaches to additive manufacturing, including metal extrusion, ultrasonic additive manufacturing, sintering or diffusion bonding.  Metal Extrusion Metal extrusion in additive manufacturing, like 3D printing, is a method where a spool of material is pushed through a heated nozzle and placed by a "printer" to layer material and create a workpiece. This process may take a few attempts to find the best parameters, design and orientation for building a component, but once found, the process is reliable for creating small intricate pieces for noncritical applications.  Ultrasonic Additive Manufacturing Ultrasonic additive manufacturing is another method of layering material, using a process of stacking metal strips and combining them using an ultrasonic weld, so to speak, to create complex geometries with internal passageways, including parts with embedded components and even parts made from dissimilar metals. Unlike metal extrusion, the solid-state weld produced by the ultrasonic process provides a reliable way to join different metals without creating brittle metallurgy, as the bonding temperature is below their melting temperature.  Sintering Sintering is a little different; while it still uses heat and pressure, this process begins with powdered metal, which is heated to fuse into one solid mass, just under the material's melting point. When using a laser, this process is known as Selective Laser Sintering, which creates intricate parts through micro-welding powdered metal layer by layer.  While ultrasonic additive, metal extrusion and sintering have significant capability in part complexity, they are severely limited by size as parts cannot be larger than the machine's build platform, and these processes face scalability issues. Materials for metal extrusion manufacturing and sintering can be limiting for manufacturers since only a small variety of metals can be used in these applications. In addition, there is a considerable cost of entry for the machine and material design and engineering and setting parameters. In extreme cases, it can take years of research and effort to develop the process parameters for specified materials in specific machines. And at the current moment, there is a lack of skilled labor and industry standards for these methods. Finally, since additive manufacturing creates many interfaces through the layering method, the part's integrity becomes a concern.  Diffusion Bonding On the other hand, diffusion bonding is different in that it can be accomplished with the age-old process of forging. Solid-state diffusion bonding is the process of adding dissimilar/similar material to a started workpiece with elevated temperature (about 50%-90% of the absolute melting point of the parent material) using applied pressure. Without melting, there is no liquation or fusion zone, which can have unpredictable structures, grain size, porosity and liquation cracking. Additionally, other types of metals that cannot be combined through traditional welding practices can be combined through diffusion.  This bonding procedure is suited for bulk items with significant size and weight and the ability to be scalable. Like ultrasonic additive, combining two or more metals has advantages for strength, ductility, corrosion, designed fail-safes, cost savings, reduced in-service inspections and more. Diffusion bonding can also provide additional benefits such as corrosion resistance or added strength while eliminating costly welding or cladding operations. Additionally, the bonded interface can be tested through conventional mechanical methods such as tensile, charpy and microstructure. At the same time, traditional non-destructive examinations , such as ultrasonic testing or liquid penetrant testing, can be completed to provide insight into the bonded surface and the base material.  This is an exciting time for manufacturing and R&D, with all of the innovations coming to fruition. But, before selecting an additive manufacturing method, or any manufacturing method, it's important to think about what you need from your project. For example, are you looking for a more budget-friendly option , do you have detailed design requirements, need to use more robust build materials or require testing? Send in your design to a Scot Forge employee-owner and explore your options.

Finding this clean-firm energy spans many industries, from mining and extraction to infrastructure and actual power generation. Sen. Tom Carper (D-Del.) remarked that “meeting our climate goals requires a well-coordinated approach across the U.S. economy — one that taps into American ingenuity and harnesses our most abundant resources, including the wind that blows off our coasts...” As a result of global warming and climate change escalation, more than 50 nations have promised to achieve “net-zero” greenhouse gas emissions by 2050. These net-zero initiatives mean producing radically lower levels of greenhouse gases while removing the pollutants we make from the atmosphere. As a result, clean energy sources like solar and wind are growing rapidly, and historic energy sources like coal-burning power plants are on their way out.  To combat extreme weather and climate change in America, Congress passed President Biden’s Bipartisan Infrastructure Deal, targeting reducing greenhouse gas emissions, expanding access to clean drinking water, building a clean power grid and more. The U.S. government is hoping that these historic investments will help reduce emissions by well over one gigaton this decade, aiming to reduce U.S. emissions 50-52% of the 2005 levels by 2030, creating a 100% carbon pollution-free power sector by 2035 and achieving a net-zero economy by 2050. Already moving in this direction, the U.S. has implemented green energy generation from renewable sources, including hydropower and geothermal power, that surpassed coal in 2020 and is now second only to gas.  Clean energy does pose a challenge as it is an irregular energy source. While wind towers and solar panels create cost-effective power, often cheaper than coal or even gas, there will be a need for massive investments in the power grid. To sustain the ebb and flow of demand, excess generating capacity and storage, will be required to provide reliable electricity and ultimately drive out greenhouse emissions. So, suppose wind and solar are pushed to do the heavy lifting themselves. In that case, this strategy ends up being much more expensive and demanding land and infrastructure than other possible pathways. A recent study sponsored by the Environmental Defense Fund and the Clean Air Task Force concluded that to meet its net-zero pledge by 2045, the state of California will need power that is not only “clean” but “firm.” Incorporating “electricity sources that don’t depend on the weather” and do not have limitations in how long they can produce power, as batteries do. The same is true worldwide, and nuclear offers a relatively stable energy source.  Nuclear power can play an essential role in a low-carbon world by providing “clean firm power,” despite longstanding concerns over its safety. The Wall Street Journal reported that worldwide, 450 reactors generate 10% of the total electricity consumed today, down from more than 15% in 2005, thanks to a rapid global build-out of power capacity that has largely left nuclear behind. Nuclear power in the West will collapse like coal generation unless aging reactors are replaced with new plants. The next generation of nuclear reactors, such as small modular reactors (SMRs), could give the world a vital tool for reducing carbon emissions. According to the U.S. Department of Energy, advanced SMRs offer many advantages, such as relatively small physical footprints, reduced capital investment, the ability to be sited in locations not possible for larger nuclear plants and provisions for incremental power add-ons. In addition, through the intentional engineering for safety, many precautions needed for large reactors are not required for small reactors as they offer more significant safeguards and security advantages.  Finding this clean-firm energy spans many industries, from mining and extraction to infrastructure and actual power generation. Sen. Tom Carper (D-Del.) remarked that “meeting our climate goals requires a well-coordinated approach across the U.S. economy — one that taps into American ingenuity and harnesses our most abundant resources, including the wind that blows off our coasts...” At Scot Forge, we believe the state of the environment is the ultimate, global employee-ownership program. Our responsibility is to leave it better than we found it, preserving our world for future generations.  Whether your team needs reliable parts to sustain net-zero or is working on R&D for things like carbon extraction, SMR design and mass energy storage , Scot Forge employee-owners can help. We strive to be an extension of your team, bringing more than 125 years of metal shaping knowledge to your project.

Reshoring provides your company with superior quality and consistency of your product, along with more control over the manufacturing process as well as better distribution and delivery options. This year proved that no industry is safe from the aftermath of COVID, which has shown no mercy as all companies are linked together in the supply chain's universal truth. The further away your product is from its final destination, the more of a pain you are probably feeling, and as a result, mitigating this pain and avoiding it in the future are probably top of mind.  Reshoring, the manufacturing of components, seems to be the answer, or at least the flavor of the month, for alleviating unknowns, delays and costs stemming from expediting or finding new methods to get your products where they need to be. So, let's take a look at what this answer provides. Reshoring for Manufacturing Assurance of a domestic source of supply Guarantee your parts aren't stuck on a ship Receive an immediate response from a supplier to get products delivered Reduce shipping delays, costs and dilemmas Cut tariffs and unknown future tariffs diminishing profits Reshoring does generally come with higher prices for various reasons, which is why it is essential to find a partner who can help you reduce the total cost of your production and maximize the value you're getting for the price. Although brokers try to reduce the price by outsourcing suppliers and modifying processes, the outcome can impact your end-user when they receive an inferior product or costly delays. Additionally, you lose control of your IP and design the further away your manufacturing gets from you. Therefore, the money you may save today may cost you in the long run. However, when you find a partner that reduces total cost through providing value, you maintain everything that makes your product unique with quality and delivery you can rely on.   Reshoring for Quality & Delivery Reshoring provides your company with superior quality and consistency of your product, along with more control over the manufacturing process as well as better distribution and delivery options. As a byproduct, reshoring helps the US economy. It removes language and time barriers while allowing you to efficiently perform on-site visits and resolve any problems that may arise quickly. Reshoring for Control To ensure efficient manufacturing of your components, you will want to provide prints or models to your supplier, which is why trust is critical. Reshoring your components is an excellent option to keep you in control to ensure you receive the materials and components that meet your requirements. At Scot Forge, we look at: Drawings:  Has the drawing specified all witness requirements? Does the drawing include testing specifications? Are there flow-down requirements? Material Specification:   Is it the most effective to meet your requirements? Is the material you are specifying commonly available in the US?  Forging:  Can it be forged? Can our expertise in working with specialty alloys and complex shapes save you time and money in downstream processes? Process:  What other secondary operations are required? Quality:  To meet the quality standards of your product, does it need to be re-engineered, redesigned and retooled? Reshoring for IP Protection As you can see, manufacturing a forging requires a partnership with a company that not only has knowledge and expertise but is one you can trust. Although an overseas supplier may fill out an NDA like a US supplier, do you know how that country will enforce it or protect you? And, by the time you find out about an NDA breach, it could potentially be too late, and your IP already compromised. Furthermore, your company could discover that the overseas supplier has found creative ways to cut corners through subpar material or processes. Unfortunately, by the time something like this is discovered, you have little recourse.  Reshoring with Scot Forge When starting a new project, Scot Forge can provide design evaluation, collaborating to ensure the most effective manufacturing processes are chosen to help you meet all requirements and provide a competitive advantage in the marketplace. You can also use our team as an extension of your own with our in-house metallurgy expertise . You have the opportunity to take advantage of Scot Forge's engineers and get a thorough review of your entire process from forging to finish machining - supporting your project in its entirety, not just the component alone. Contact us today for a free consultation.

More than 40 years later, Scot Forge continues to be a proud, 100% employee-owned company. On the surface, our ESOP is a retirement plan, but within our day-to-day operations, it serves a greater purpose. In 1978, former owner Pete I. Georgeson sold Scot Forge to his employees, giving way to the Scot Forge Employee Stock Ownership Plan (ESOP). More than 40 years later, Scot Forge continues to be a proud, 100% employee-owned company. On the surface, our ESOP is a retirement plan, but within our day-to-day operations, it serves a greater purpose. We asked four employee-owners to expand on what they believe it means to be a part of an ESOP company. Here is what they had to say! Mark Dowell : Blacksmith, has been an employee-owner for 14 years. Richard Hobday : Spring Grove Plant Manager, has been an employee-owner for 5 years. Sarah Marski : Inside Sales Manager, has been an employee-owner for 17 years. Michelle Riedel : Manager Executive Office Operations, has been an employee-owner for 20 years. What does being an employee-owner mean to you? Mark : "It means that I personally have a say within the company we own together. It also means that I have an obligation to bring to work the best version of myself and expect the same from others. Being an employee-owner gives me confidence that I have support in my daily tasks and decisions." Richard : "Being an employee-owner cultivates a sense of pride in what you do and creates a feeling that you can come in and be a part of something bigger than yourself. We have an interconnected fate with our employee-owners, our customers and our suppliers. Personally, I've fallen in love with our model and what we stand for as a company. As an employee-owner, we are constantly learning from yesterday's performance through building a learning organization." Sarah : "It means more than having a 'regular job' because you have ownership, responsibility and accountability. Being an employee-owner gives me a sense of pride knowing what I work on is mine and that it is helping the company progress." Michelle : "It means I have a team of hardworking people, with similar values, around me every day. When you own a business with 500+ other people, it's important that you are aligned and work together to be successful. After all, it's up to us to create value for our retirement and preserve the company for future generations. Being an employee-owner is special – being a part of this great company and serving my fellow owners is such a privilege."  What does employee ownership do for your future? Mark : "Employee ownership at Scot Forge has historically set up employees for a successful future, financially. I am a firm believer that as long as, we as owners, remember the core values that were built and developed by the Scot Forge owners amongst and before us, and we continuously grow as one, the sky's the limit for what our future can hold." Richard : "We are here to develop ourselves, to pass on what we've learned to others and to create a legacy and to give back. Being an employee-owner has helped me prioritize helping others win at work and in life, which to me is the most enriching gift you can give." Sarah : "When I think of future responsibilities, it makes me want to work harder to make the company better. There is also an aspect of security that comes with employee-ownership because I am not worried about my financial future." Michelle : "This question is two-fold for me. Obviously, the financial piece is important to have a secure retirement. But, it's the other things I've learned along the way as an employee-owner that I feel will also serve me well in the future. Teamwork, personal accountability, the value of safety, continuous learning and serving others are all characteristics that will help me in the next chapters of my life. So many of these qualities are on display by others around me every day."  How does employee ownership affect your day-to-day? Mark :  As owners, we depend on one another to strive for excellence. When we genuinely focus on our day-to-day operations to win the day, we continuously improve for tomorrow. No matter the obstacle, if we approach our challenges together head-on, we will rise above what's expected for our customers, our company and our future." Richard : "Our culture is not a natural act, [in that it doesn't happen by accident], and we are constantly reminding ourselves of our responsibilities and not just our rights. In terms of our leadership, it's about ensuring we are working for our customers every day. Keeping [our customers] in the path of our work. We all have a lot of responsibilities, and actually owning a piece of the company keeps you accountable - knowing your work makes a difference." Sarah : "Everybody wears a lot of hats around here, and you do what needs to be done when you see something that needs to be accomplished. Day-to-day you're busy, but it pays off." Michelle : "Whether I am making a purchase on behalf of the company, serving a member of our community or taking a class to improve or learn a new skill, I do it with integrity, knowing that I am accountable to and represent 500+ other owners. Our employee-owned company has a mission statement that I strive to live up to every day. Keeping the values in front of me reminds me who I'm here to serve and what the expectations of being an employee-owner are."  How would you explain an ESOP to a future owner? Mark : "[An] ESOP is a great personal opportunity and time investment. It's a plan by which a company's capital stock is bought by its employees. Scot Forge is 100% employee-owned. Thanks to previous employee-owners, I and others have been set up with a solid base and structure for success heading into the future. In my opinion, people in the market for a career opportunity should highly consider ESOP companies. The benefits from non-ESOP companies cannot compare." Richard : "Our ESOP is a retirement plan, not a retirement job. If we do the right thing for each other and our customers, we earn the right for our company to become more and more valuable over time. Our ESOP plan requires teamwork and collaboration amongst our employee-owners to win. It's a delicate system that, if nurtured and cared for, will be passed on for many generations to come." Sarah : "An ESOP is an opportunity to be a part of something bigger than yourself. It's an opportunity to work towards something to help both you and your fellow employee-owners. So if you want more than a job and are looking for a career and a second family, employee-ownership and our culture at Scot Forge is the way to go." Michelle : "An ESOP is a plan that provides employee-owners shares of the company's stock that is built-up over the lifetime of their career at the company.  Every employee-owner creates the value of that stock by the way we: stay safe, continuously improve processes, look for cost savings and [focus on the] quality of our work to name a few. The more value we create together, the greater our stock price and, therefore, a larger account balance for retirement.  It takes all of us to create the value of our company though, not just one person, department or plant can do that – we must all do it together as employee-owners."

Even if you are experienced in defense and military projects, finding and partnering with a supplier who has extensive experience with mil-specs and DOD stipulations is critical for meeting essential deadlines and requirements. For many companies, finding new revenue streams is essential for 2021, so looking to markets never worked in before, such as government contracts or manufacturing for our military, may be on the horizon. For other companies, keeping up with the U.S. Military and National Defense's innovative demands could be at the forefront of the initiatives. Either way, finding and partnering with a supplier who has extensive experience with mil-specs and DOD stipulations is critical for meeting essential deadlines and requirements.   Proven Track Record with the Defense Industry Scot Forge employee-owners are trusted partners for the U.S. Military and National Defense because of our ability to solve our military's toughest design and manufacturing challenges . We achieve intricate, near-net shapes and mechanical properties while engineering new ways to forge atypical geometries, which may have previously been considered impossible. As a small business, we take it upon ourselves to offer reliable quality and repeatability to consistently demonstrate our commitment to surpassing our defense and military customers' demanding needs. In addition to these needs, we demonstrate our commitment to the United States through domestic sourcing and manufacturing.  We Create Custom Components for Military & Defense Contracts As an experienced supplier, our Scot Forge Defense Team can be critical in filling in the knowledge gaps. When you work with a team specialized in defense services, you can expect a dedicated account manager supported by our forge development team and metallurgists' knowledge and experience . We work with you to provide high-strength metal components for defense applications while meeting the most stringent requirements.We forge components for the following and more for military and defense: Submarines Tanks Aircraft Carriers Destroyers Ordnance Ships Missiles Military Vehicles The Scot Forge Quality Assurance Program provides complex review and Level I certification for all forged defense and military components . Our QA program gives us the ability to confidently create and deliver unconventional near-net-shape forgings for several of the United States' most critical defense programs and applications. A Company Culture Focused on Quality & Safety Our Employees are Invested We not only invest the time in understanding a project and its requirements; we also have reinvested more than $250 million of our own money back into our company over the past four years to acquire and build the assets to support the next generation of owners, which prepares us to support the future demands of our country. Even in uncertainty, we continue to grow and remain steadfast for our military and defense customers' needs.  We Strive for Continuous Improvement At Scot Forge, continuous improvement is in all aspects of the business, not just production. We believe this core value, along with our quality culture, stems from every employee having ownership in Scot Forge. We're a 100% Employee Stock Ownership Plan (ESOP) company . This unique culture fosters an environment where new and creative ideas to improve are encouraged, benefiting both the customer and the company. Every employee-owner takes pride in the company's performance and shares in its successes. We realize the importance of our work and strive to move to a new level of performance to ensure our soldiers’ and the nation’s safety. Committed to Meet Budgetary and Timeline Deliverables Technically Trained Defense Services Team Our dedicated team of front-line technical experts for defense services, backed by our metallurgists and forging experts, work directly with you to uncover ways to reduce long-term costs and improve lead times. We have a proven track record of solving the military’s toughest metal challenges. Our industry specialists can help you meet your design challenges, including redesigning cast or fabricated parts and program objectives with clear communications on everything from order status to valid certification and milestone achievements. Committed On-time Delivery and Breakdown Services At Scot Forge, we understand the importance of on-time delivery and maintaining your build schedule. In critical circumstances, reduced lead times can be offered for breakdown and emergency orders in need of immediate production response. Extensive Ferrous & Non-Ferrous Materials Inventory We maintain an extensive inventory of ferrous and non-ferrous materials. From vacuum degassed air melt to ESR or VAR cleanliness levels, forgings are supplied using the highest-quality material. Defense application-specific grades include HY-80, HY-100, N04400, N05500, N06625, 6-4 Titanium, CP Grade 2 Titanium, C63200, C71500 and custom-melt alloys that meet OEM specifications. Fanatical About Safety Scot Forge's employee-owners deliver quality products, on-time, without compromising safety or adversely affecting the environment. By combining teamwork with continuous improvement, our culture focuses on sending each employee home safe every day. Year after year, OSHA and the Forging Industry Association recognize Scot Forge for our outstanding safety performance. Every day, we purposefully strive to be safer and better than we have ever been. In 2019, Scot Forge was recognized by EHS Today Magazine as one of America's Safest Companies . Our company initially won the award in 2014, becoming the very first forging facility in the United States to receive this safety recognition.   Contact us today to learn more about partnering with a forge industry expert like the Scot Forge Defense Team.   Relevant Resources ●    Dr. Peter Navarro and Navy Secretary Richard Spencer Visit North American Forgemasters ●     Scot Forge Markets: Defense ●     Scot Forge Markets: Aerospace