A popular thought is that the mining and drilling industries are to blame for the state of the world; however, there are benefits to mining that cannot be overlooked. As people focus on preserving the planet's natural resources and are leaning more heavily on renewable energies, the popular thought is that the mining and drilling industries are to blame for the negative state of the world. However, while we do need to be aware of our carbon footprint, there are benefits to mining that cannot be overlooked.  (Discover the full infographic at https://mineralsmakelife.org/resources/our-energy-future-depends-on-mining/ ) The mining industry supports our everyday life. The mining industry not only provides the elements for the innovations of tomorrow, but the U.S. minerals industry also supports more than 1.1 million jobs. In addition, estimations indicate that another 3.5 additional jobs are created elsewhere in the economy for every metal mining job compared to every non-metal mining job producing around 2.6 other jobs. With mineral mining directly employing more than 400,000 Americans today, and more than 700,000 indirectly employed, the mining industry is a significant driving force in our economy.  Aside from supporting thousands of jobs, the mining industry provides raw materials, minerals and metals critical to our economy. They provide the foundations for modern living, innovation and engineering achievements. Take platinum, for example; it is used in more than 20 percent of all manufactured goods. Platinum is essential to creating everything from personal computers, flat-screen TVs and hybrid cars to life-saving medical devices. Today, the National Mining Association (NMA) reports that U.S. manufacturers rely on 29 of the 35 "critical" minerals, as the Department of Interior designated, essential to a strong U.S. economy.   Mining to Protect Health, Save Lives Life-saving medical devices would not exist without many of the metals and minerals that are mined. There are even medicines that doctors and patients rely on every day that would not be available. For example, minerals are crucial materials to operate CAT scan devices. Copper, silver and gold are mined here in the United States to support these machines. Lithium is found in pacemakers, defibrillator machines and other portable electronic equipment, while titanium is used in surgical pins, bone plates, wires, rods, stent-electrodes and screws. These are a few ways Americans and the world rely on metal and minerals for their health. Mining for Advanced Energy Technologies Renewable energy technologies rely on minerals. Copper is just one of these minerals. It is used in the wiring of solar panels and plays a significant role in components for wind turbines. Not only is this mineral a key player in energy production, but it also is critical to renewable energy storage as copper is used in lithium-ion batteries. On the topic of energy storage, another mineral frequently used is manganese. It is an additive in steel alloys and is found in electric vehicles and wind-and-solar power-storing batteries, along with lithium. Only procured through mining, these metals and minerals are also in both off-shore and on-shore wind power projects . Mining to Keep Americans Safe Metal and minerals are vital components of our national security; the United States Department of Defense utilizes more than 750,000 tons of metals and minerals annually, which have U.S. sourcing requirements. For example, armor plates are comprised of chromium, nickel and molybdenum combined in precise amounts and applied to purified scrap metal to protect people by withstanding explosions and gunshots. At the same time, airborne equipment employs beryllium to detect and destroy improvised explosive devices (IEDs). Mining , directly and indirectly, impacts all of us every day, from the phone that connects you to the world to the innovations in renewable energy that power homes and vehicles. Scot Forge helps support mining by developing and manufacturing forged components that are more sustainable as they require less material and are reliable, creating less scrapped parts and waste.

Looking at how traditional casting designs could take advantage of today's technological advancements in forgings. In some industries, castings have historically been “known” as the way to design and produce a part. At the time, purchasing a casting made sense due to the geometry or configuration of the part. However, today there are many reasons to look at converting castings to forgings. To start, you first need to understand the difference between these two metalworking processes. In the simplest terms,  • Casting is the process of heating metal until molten. While it’s in the molten (liquid) state, it is poured into a mold or vessel to create the desired shape. • Forging requires heating the metal to its point of plasticity, then hammering, pressing, or rolling to shape the part. When forging a part, better uniformity of composition and structure is achieved. During the forging process, recrystallization and grain-refinement occur, resulting in increased strength. The most common complaint about castings is porosity – voids in the finished component during solidification. Based on the location of porosity, the component may need to be welded or scrapped. Most castings failures are due to porosity, lower tensile or fatigue strength, and defects. You may not know whether or not a casting can maintain its integrity until it fails because castings do not have consistent grain structures. Properties in cast metals are inconsistent due to how the metal settles in the mold and the rate at which each casting cools. Forging, on the other hand, is more dependable by nature because the forging process strengthens metal while forming it by directing grain flow. The forging process eliminates porosity through the compression of the material, achieving a 3:1 minimum reduction. Forging also lessens the need for expensive alloys to achieve desired metallurgical properties. Today, there are more options to achieve a unique-shaped part. Forging technology has made significant strides in the past decade and now can offer complex shapes, which traditionally were thought to be casting-only pieces. This type of near-net-shape forging allows you to explore options beyond castings. The casting to forging conversion process can be very straightforward if you have design authority and are open to design change. Considering all the costs in a product’s development through the lifecycle, the long-term benefits of forgings outweigh the short-term cost-savings that castings might seem to offer. So, where is the best place to begin when looking to convert a casting to a forging? First, you must understand that not all parts can or should be made as forgings; castings work well for a variety of applications. It’s best, to begin with evaluating the piece in question.  •  What is the application and environment of the component? •  Will voids in the part affect product performance? •  Do you frequently have to scrap parts due to porosity issues? •  Do welding and repairs cause a frequent pain point? •  Does the part in question play a crucial role in overall performance? •  Does your team have design authority? •  Is the part mission critical? •  Does reducing risk by removing vendors from your supply chain make sense?   Don’t get stuck with a traditional design that doesn’t take advantage of today’s technological advancements. The best results occur if you’re willing to think creatively and challenge traditional methods. By working with a metal forming expert you can evaluate your casting to see if a forging makes sense, the employee-owners at Scot Forge have this expertise to help you find the best solution. Feel free to email us today.

The frustration felt by manufacturers and consumers hasn't stopped chip industry stocks from skyrocketing to all-time highs. "The PHLX Semiconductor Index (SOX), which tracks dozens of the largest chip-related stocks, has gained more than 70 percent in the past 12 months," according to MarketWatch. Currently, there's a global shortage of semiconductors, which are predicted to be in short supply through 2021 and beyond. The industry struggles to meet demand due to various factors: The digital push since the start of the COVID-19 pandemic Demand for electronics U.S. China trade war The incredibly high demand for chips has impacted automakers and consumers around the world. Automakers, General Motors and Ford, claim they've had to cease production of specific vehicle models because of semiconductors' absence. According to a recent MarketWatch article[1], Maribel Lopez, a principal analyst at Lopez Research, explains that the industry faces a "perfect storm" of demand and supply issues that are unlikely to resolve anytime soon. People expected high demand for mobile-device chips; however, the pandemic caused another level of instability to supply chains and the manufacturing processes to produce semiconductors. The frustration felt by manufacturers and consumers hasn't stopped chip industry stocks from skyrocketing to all-time highs. "The PHLX Semiconductor Index (SOX), which tracks dozens of the largest chip-related stocks, has gained more than 70 percent in the past 12 months," according to MarketWatch. Unfortunately, some experts believe there's no rainbow in sight. Stifel analyst Matthew Sheerin, who follows tech supply-chain issues, believes, "We don't see any major correction on the horizon, given ongoing supply constraints as well as continued optimism about improving demand in 2021." Stifel goes on to say, "We remain more concerned with continued supply disruptions, and increased materials costs than we do an imminent multi-quarter inventory correction." Working to Tighten the Gap Many chip-equipment suppliers seem optimistic that manufacturers will increase capacity allowing for improved designs that won't be well-served by current fabrication facilities. For example, Applied Materials, Inc. expects to supply a decade-plus investment cycle for chipmakers. Additionally, strong earnings and outlooks from chip-making equipment companies KLA Corp. KLAC, 1.29% and Lam Research Corp. LRCX, 3.67% noted that chip makers needed to build out their manufacturing capacities even further. To that point, Taiwan Semiconductor Manufacturing Co. TSM, 1.68%, the third-party manufacturing giant that fabricates silicon for many chip makers like Apple Inc. AAPL, 2.31% and others said it plans to spend $28 billion to build out its facilities in 2021. Improved Semiconductor Manufacturing Processes Can Help Scot Forge recently began forging components for semiconductor manufacturing equipment. Working with one of our customers, we were able to deliver significant material reductions and improved supply chain lead time. "When we work with a new customer, we analyze their processes and look for ways to save material costs and increase efficiency. Working with one of our semiconductor manufacturing customers, we eliminated labor and overhead cost associated with removing 70 percent of input material, which dramatically reduced overall material spend. We believe that if more manufacturers were to improve components structure through near-net forgings and dramatically reduce materials and lead times, more manufacturers could become more efficient and improve the supply-shortage situation." - Matt Davis, Defense , Aerospace & Semiconductor Sales Engineer Forging Components Benefits  Semiconductor Manufacturing Equipment  Using forged components for semiconductor manufacturing equipment can eliminate capital expenditures for milling equipment and decreased process time. Historically, semiconductor manufacturing equipment components are produced by machining a block of material to achieve the desired shape. However, using the advanced forging process can save time and money. Forged Components Are Stronger Forgings have an inherently superior molecular structure compared to cast or fabricated parts due to the grain flow and material reduction achieve through the forging process. Scot Forge takes these benefits one step further with near-net shaped forgings, which provide a shaped part that reduces machining time and material cost. You no longer have to machine out a hexagon or an octagon from a block for a transfer, vacuum or pressure chamber. Our forgings can get you closer to your complex shape while maintaining quality and delivering reliability. The bottom line: If semiconductor manufacturers can prolong their machine components' lives, improve processes, and increase efficiency, the global semiconductor market may see correction sooner than later. [1] Witkowski, Wallace. 2021. “Worldwide Chip Shortage Expected to Last into next Year, and That’s Good News for Semiconductor Stocks.” MarketWatch. February 22, 2021. https://www.marketwatch.com/story/worldwide-chip-shortage-expected-to-last-into-next-year-and-thats-good-news-for-semiconductor-stocks-11614020156 .

Scot Forge was able to forge a complex shape of a tension ring in two halves for a major oil rig project. Learn more how Scot Forge assisted this customer. At Scot Forge, our goal is to exceed customer expectations with every conversation we have, order we process and product we forge. We aim to build long lasting relationships with all of our customers to show each of them they are valued and placed in the capable hands of our dedicated employee owners. An oil rig requires the use of a tension ring as the point of connection between the tension system and the riser string. The tension ring holds the riser string stable during the drilling and pumping process. These parts are typically made as castings or weldments; however, one of our customers needed an alternative due to lead time and quality issues. Scot Forge collaborated with our customer to provide an innovative forging solution. Using one of the largest commercially available ingots, Scot Forge was able to forge the complex shape of the tension ring in two halves. The initial forgings were made at our NAF plant and then transferred to our Spring Grove facility for heat treating, testing and machining. As with most projects where we are creating something that has never been done before, there were obstacles. However, we were able to learn as we worked through the issues and ultimately delivered a quality forging within the time frame needed. Shortly after the piece was finished, the oil and gas industry diminished, but our customer's eyes were opened to Scot Forge's capabilities in forging complex pieces. Collaboration between our customer and the Scot Forge process, engineering, engineering sales, production and forge development teams, played a crucial role in this project. By everyone working together toward a shared goal, we were able to create a solution to a common pain point.

A 2019 report published by the Center for Strategic and International Studies predicts the world needs an estimated $94 trillion in infrastructure by 2040. Reconstructing the world's foundation will unveil opportunities for US contractors, energy producers and suppliers, tech developers and service providers and investors, leading to the growth of the US economy, jobs and a return on investment. The movement for major global infrastructure has never been more essential to our nation's future and leadership as it is today. Within the next 15 years, countries around the world will invest in hard infrastructure. These infrastructure projects, emphasizing transport, energy, information, communications technology (ICT) and water sectors, have been long-recognized as the backbone of modern economies.  A 2019 report published by the Center for Strategic and International Studies predicts the world needs an estimated $94 trillion in infrastructure by 2040 . Reconstructing the world's foundation will unveil opportunities for US contractors, energy producers and suppliers, tech developers and service providers and investors, leading to the growth of the US economy, jobs and a return on investment. Additionally, maintaining the stability of ports, bridges, pipelines, fiber-optic cables and other essential infrastructure is imperative to US security and our nation's military presence.  Infrastructure and clean energy stocks have been on the rise since the presidential election, according to CNBC.com . Infrastructure has been at the top of Joe Biden's plan since the beginning. He's had a $2 trillion plan that's going to invest in roads, highways, airports, ports as well as digital infrastructure and cleantech," says Jay Jacobs, senior vice president and head of research and strategy at Global X ETFs. Considering these stakes - among several others - the US is now making global infrastructure projects a significantly higher priority. An Opportunity to Set Global Standards In addition to short-term economic boosts, the US investment in infrastructure implies a list of broader, longer-term interests to promote sustainable and inclusive development of global standards, ensure high-quality infrastructure, and mitigate impacts on stability ensuring optimal performance of the global systems. Forgings, which appear in roughly 20 percent of products representing the US GDP, are essential to the US industrial economy society and its national security.  Metal forging technology has evolved over the past couple of decades due to industry demands seeking a greater return on investment, increased capital productivity, and customer expectations for increasingly higher quality and part performance levels.  Today, forging is the most trusted, preferred process for manufacturing components due to its output of superior quality, integrity and performance required for critical and demanding applications.  Over the past 20 years, forging industry leaders have created cost-efficiencies through materials development and usage, process application, energy management and efficacy, environmental sustainability and effective human resource performance.  Forging delivers advantages that few processes can replicate. Designers and users of forged components understand the edge forging provides: Forgings are manufactured from readily available bar ingots and/or billets. Nearly all metals and alloys can be forged. Virtually no restrictions exist on part size. Forged parts possess high tolerance attributes. Products are fully recyclable. Forged components have higher strength and reliability. Forgings offer low life cycle costs. Modern forging facilities today, such as Scot Forge, feature automated, fully-integrated processing equipment that controls processing variations and produces high-quality, superior consistency and dimensional control products.  US forging companies have the opportunity to set forth international standards in which components for heavy equipment, bridges and pipelines are built with the highest integrity, safety standards and longest life span.  What Types of Forged Parts are Used in Infrastructure? Forgings are the perfect choice for many infrastructure applications, delivering the high-structural strength required in movable bridges, locks and dams, and other large civil engineering structures. Below lists the types of forgings used in infrastructure construction: Shafts : Pinions, trunnions, floating shafts, crankshafts, tower sheave shafts, rope shafts, Gudgeon pin, strut pin, link pin, diagonal fin Flats : Curved or flat racks, tracks and treads, lock bars (we can transition between round and rectangular cross-sections), receiving sockets, receiving shoes, guide housings Rings : Ring gear, hex sleeves and hex jam nuts, gudgeon collars Hubs : Sheave hub, trunnion hub, winch hub, pintles Torch Cut : Clevis, gudgeon links, anchor rods  Scot Forge: Prepared to Meet the Challenge As plans emerge and investments in global infrastructure take form worldwide, Scot Forge is positioned to lead the way.  We Bring Optimized Specifications and Manufacturing Practices At Scot Forge, it's our mission to ensure you succeed in your most critical initiatives. We produce components through innovative processes that offer forged solutions for everything from the world's physical infrastructure, energy and transportation to manufacturing, mining and national defense.  Our unique manufacturing processes have taken the place of outdated alternate metalworking methods. Using our vast inventory of loose tooling, we can develop near-net shaped solutions to meet your drawing requirements. Our extensive forging capabilities enable us to reduce forged section sizes and improve mechanical properties. Our Forging Experts Are Problem Solvers Engineers, professors and researchers come to Scot Forge for our core competencies in metal chemistry, behavior and shaping. We have helped solve challenges in historic designs with groups such as the Army Corps of Engineers by converting casting into forgings, forging components with eccentric geometries, and aiding in the design of unique shapes.  Our technical experts embrace the challenge of creative solutions and have experience working with specialty grades for applications from particle physics to prototyping for applied research. We have an on-site staff of metallurgists, four of which have Ph. Ds, and our team of forging engineers are ready to help you understand the implications and capabilities of your material and heat treat choices. Uniquely equipped to produce low-volume, non-repeating forgings, Scot Forge can help provide everything from simple bar stock to 300,000 lbs. tubes. We have also developed a unique semi-closed die forging technique that allows for the flexibility of open die forging with the closed die's near-net shape. This is that method that allows us to convert pieces originally designed as castings or fabrications to forgings that were once not possible or cost-effective. State-of-the-Art Computer Modeling & Simulation Simulation capabilities enable precise tool design and optimal forge process plans. As a result, material and machining requirements are reduced, minimizing costs and turnaround times. Our accurate simulations model a wide range of metalworking and material characteristics, including: Complex shapes Upsetting Forward extrusion Back extrusion Gear forming Stress analysis Heat treat modeling Grain flow characteristics Custom Alloy Development and Thermal Treatments  Scot Forge engineers and metallurgical experts can help your team study and evaluate alloy compositions. Our team can create a material capable of meeting the strict criteria for forged components, resulting in the development of alloys that offer better properties with potential material cost savings. Extensive Materials Inventory  Our extensive material inventory, production capabilities and experienced technical support combine to meet your most demanding requirements. Our technically trained account managers possess experience working to ASTM A668, ASTM A182, ASTM A291 and other various AREMA, AASHTO and DOT requirements. We are capable of meeting short lead times and offering breakdown services, too.

Following today’s best practices, we focus less on the lowest price and more on our customers’ total cost of ownership (TCO). Whether that means reducing manufacturing costs, improving part performance or minimizing material waste, our team brings the knowledge of custom forging experts to work in your plan and help you achieve long-term cost reductions and improved lead times. Evaluating Price vs. Total Cost How Scot Forge Adds Value Where Our Customers Need It Most As a leading forging supplier to many industries, Scot Forge understands that our strong industry relationships derive from our ability to deliver measurable value to our customers’ bottom line. Following today’s best practices, we focus less on the lowest price and more on our customers’ total cost of ownership (TCO). Whether that means reducing manufacturing costs, improving part performance or minimizing material waste, our team brings the knowledge of custom forging experts to work in your plan and help you achieve long-term cost reductions and improved lead times. TCO: Best Practices to Help Buyers Determine Real Costs vs. Price In the past, the gross profit margin was a measure used to determine profitability. The basic equation of subtracting the cost of goods sold from net sales assumes that the easiest way to reduce the costs of goods sold would be to reduce the purchase price of materials and components. However, price is only one part of the picture. To evaluate value solely based on price can lead to higher costs overall. Think of this: do you value a supplier who also offers valuable knowledge and resources to help you solve problems? Many companies now realize that effective partnerships motivate suppliers to spend their limited resources with their partners vs. those who only focus on price. Instead, companies can partner with a few suppliers who hold the expertise to look at the big picture. Manufacturers who have insight into how their products impact their customers’ operations, and a longer view of the supply chain, can make specific recommendations for improvements. The value can significantly contribute to the bottom line. Scot Forge adopts TCO practices with its customers to help them improve efficiencies, costs and lead times. Optimizing Your Specifications and Manufacturing Practices Our technically trained account managers, Forge Development team and metallurgists can increase your product value with customized solutions that meet your existing requirements. Even the simplest material change or process modification has helped many Scot Forge customers realize significant savings. Below are some measurable examples of how Scot Forge reduced the total cost of ownership (TCO):  Improved Lead Time  Past practices on a customer part called for normalizing, quenching and double tempering; however, these practices ran up costs and production times. After discussing the end-use application and requirements, our team realized these were unnecessary steps that would affect the part performance. In fact, these steps were only added to solve a consistency problem their previous supplier was facing. By eliminating the normalizing and second tempering operations, enhanced the profitability of their component, and reduced lead time by weeks.  Previous requirements on another customer component called for meeting both a minimum tempering temperature and a hardness range on certain parts; this process often resulted in a re-quenching operation, which resulted in lengthened lead times. Through temperature modification, Scot Forge met the specification the first time and shortened the lead time by four weeks.  Lower Part Costs  A customer was looking for cost reduction assistance with a gear application to meet the hardness requirements of the 4340 material initially specified. Our team recommended substituting another 4100 series material for 4340, which lowered part costs by 10% while still meeting minimum Brinell requirements. Another customer was previously specifying Vacuum Arc Remelting (VAR) material for a pinion shaft in another scenario. Lead times were unacceptably long, and the material costs were high. Scot Forge realized that by switching from VAR material to another cleanliness technique, the customer would reduce their lead time by months and reduce material costs by more than 45% - without sacrificing product quality.  Reduce Marking Costs For part identification purposes, a customer previously specified elaborate markings on each part, then routinely machined them off upon receipt. Scot Forge introduced a more efficient process that uses a simple purchase order and heat number to identify each part, saving time and excess marking costs. Innovative Engineering Brings Solutions Over Products Our Forge Engineering team brings more than 90 years of combined experience to your project, including first-hand blacksmithing and modern simulation technology. They have developed a unique semi-closed die forging technique that allows for the flexibility of open die forging with the near-net shape capability of closed die. This method enables converting pieces with unique geometries, from castings or fabrications to forgings that were once thought impossible or cost-prohibitive.  Computer Modeling & Simulation Reduces Costs and Turnaround Times Our Forge Engineering team possesses a full range of simulation capabilities that enable more precise tool design and optimal forge process plans before producing an actual forging. As a result, material and machining requirements are reduced, minimizing costs and turnaround times. Our accurate simulations model a wide range of metalworking and material characteristics, including:  Complex shapes  Upsetting Forward extrusion Back extrusion Gear forming Stress analysis Heat treat modeling Grain flow characteristics Custom Alloy Development Can Save Material Costs, Scot Forge in-house engineers and metallurgical experts can join your team to study and evaluate alloy compositions. We can help you create materials capable of meeting the strict criteria for forged components used in markets such as maritime , gearing , power generation , aerospace and defense applications. The result is the development of alloys that offer better properties with potential material cost savings.  A real-world example: As an extension of our customer’s team, Scot Forge industry experts discovered a recurring roadblock during joint discussions around their forged aluminum products - the customer needed aluminum with excellent fatigue endurance, toughness and corrosion resistance characteristics. Our in-house team worked with outside experts to evaluate suitable aluminum alloy compositions capable of meeting the strict criteria for forged components used in naval, aerospace and defense. From this collaboration, we discovered a variation of aluminum 6013 that, with a thermal treatment, adapts well for many forging applications. Scot Forge devised a proprietary processing method for aluminum 6013 and dubbed it Highlander 613™. Originally, Scot Forge developed Highlander 613™ as a better alternative to the traditionally forged alloy 6061. However, after reviewing and optimizing the material’s forging properties, we have also found it to have substantial benefits compared to aluminum alloys of the 7XXX and 2XXX series as an all-around versatile product. Partner with Us If you're ready for a partner to develop solutions for your project, Scot Forge and its team of engineers can deliver. Our knowledge and expertise will help you reduce costs, improve lead times and offer innovative ideas to lower your total cost.

Learn more about ultra-clean metals produced through a process called Vacuum Arc Remelting and the benefits they bring to forged bar. Bar Forgings are used in many applications, from ship shafts to gears in machines we use daily; and bar forgings found in high-value applications, such as applications that undergo extreme conditions, need metal grades of the highest quality. To reach these qualities, engineers can choose “exotic” metals, which inherently hold choice qualities. But, with these high-end materials come high-end prices. Another, more cost-effective, way to reach high-quality material properties is through remelting processes like Vacuum Arc Remelting or Electro-Slag Remelting. Both VAR and ESR help to produce clean material , reducing segregation and inclusions in steel or other alloys, refining them and improving grade properties – VAR is prevalent in the United States and ESR is more commonly seen in Europe, although U.S. ESR furnace capacity has been increasing over the past few years. The benefit of Vacuum Arc Remelting is cleaner materials with: reduced gas and oxide contents, improved homogeneity of the ingots obtained; improved ductility; greater uniformity of properties in the transverse, and longitudinal directions; improved fatigue properties; and uniformity of chemical composition. To produce these ultra-clean metals, VAR materials go through a secondary melting process conducted in a vacuum-sealed, highly controlled environment. The steels and alloys gain tight chemical tolerances through the removal of dissolved gases, such as hydrogen and nitrogen (if desired); the reduction of undesired trace elements; directional solidification of the ingot from bottom to top, which alleviates macro-segregation and reduces micro-segregation.  As mentioned above, VAR also provides oxide removal that is achieved through chemical and physical processes. The chemical process happens because less stable oxides or nitrides are thermally reduced by the carbon present in the alloy, allowing them to then be removed through the vacuum of the VAR process. However, in special alloys and high-alloyed steels, the non-metallic inclusions (e.g. alumina) are very stable, so they remain in the chemical makeup of the material. Other inclusions in the ingot will be removed physically by flotation that takes place during remelting (impurities float to the top where they get cut off). Any remaining inclusions are broken up and evenly distributed in the cross-section of the solidified ingot. VAR grade materials are found in aerospace applications, including the “superalloys” needed for extreme applications of temperature and pressure. VAR steels are used in rocket-booster rings, landing gear and high-pressure tubes. Oil and gas , as well as the nuclear industry , are utilizing the remelt of reactive metals and their alloys. Typical VAR grades: 4340 VAR9310 VARPH Stainless300M3NiCrMoV300 & 400 Series Stainless To learn more about VAR grade properties and availability, contact a member of the Scot Forge bar team today!

Marine and offshore industries often require ABS certified parts. Learn how to minimize costs and production delays while ensuring that you obtain properly certified products. Manufacturing companies that work in the marine and offshore industries or supply products for marine applications often require the American Bureau of Shipping (ABS) certification. Understanding key processes that require certification and collaborating with your suppliers can help you minimize costs and production delays while ensuring that you obtain properly certified products. Why Is ABS Certification Important? The American Bureau of Shipping was chartered in 1862 to certify ship captains. Since then, it has developed and set safety and quality standards for ships and offshore structures.    Globally, ABS Standards ensure that the materials, parts and components, and construction of vessels and marine equipment meet established safety standards. ABS works with the marine industry worldwide as they develop new technologies for constructing marine vessels and offshore structures, revising and updating its certifications to meet the changing industry needs. ABS Certification Rules & Guides The ABS-established Rules and Guides for certification provide standards for the design, construction and periodic survey of marine vessels and offshore structures to promote their safe design and assembly. Materials, parts and components used in the manufacture of naval ships and structures must meet the craft's set standards or requirements. The Rules specify requirements to meet the needs of a particular component. It’s typical for forgings to use Steel Vessel Rules Part 2 Chapter 3 part 7 (which was moved to Publication No. 1 Marine Vessel Rules MVR in 2020). Within this section, you will find ABS Grade 2 and other commonly used ABS grades for forgings.   If you are building offshore components, you may need to reference MODU (Mobile Offshore Drilling Unit) rules, which switched to MOU in 2020. This is located in Publication No. 3 of the Rules.   The end use of the component determines the Rules required and any requirements for survey during manufacturing: Individual components used in the construction of the vessel or structure may need certification based on the Rules Some of those components must be surveyed as they are being constructed or fabricated to verify that the process meets ABS standards. How to Determine ABS Requirements to Minimize Risk and Cost   ABS certification costs time and money. Surveyors visit on-site to verify your processes meet the standards during manufacturing, construction or fabrication. This can be expensive. By understanding the Rule requirements for your product, you can identify the supply-chain stages where inspection and certification should occur. In doing so, you'll save your company time and money and minimize your products' risk not being certified.  Through following a few guidelines, you can better prepare to meet certification standards unique to your component or part while saving time and money. What is the intent of the certification? Suppose your component is intended for a classed vessel . In that case, ABS Rules must apply to receive this type of certification (possibly working only to ABS Rules, or in conjunction with an industry-standard such as ASTM, or customer proprietary specifications that have been reviewed and approved as an appropriate design for the application). If the certificate is for verification purposes only , it is very important for your supply chain to understand this. ABS Rules do not apply in this case, and it must be discussed to what end ABS must be involved. For example, what operations are to be inspected? In this case, the ABS Rules do not apply to govern what requires survey, and therefore the designer must flow down this information. Identify the application that will use your component Are you manufacturing a component for a jacking system (or the complete system), for torque-transmitting parts or for a structural element, for example? The application helps determine the appropriate section of the Rules or Type Approval Tier for your piece. Know the end-use of the part The end use of the part determines which ABS Rules are required. If your piece is a reduction gear, the testing requirements will be different from those of standard gear. Obtain an ABS-approved drawing or Design Approval Document These drawings or documents show that ABS has approved the design and provide an approval number for reference. This also helps determine what year of the Rules the vessel was designed to, so we know which edition is required for appropriate compliance. These drawings also include critical flow-down requirements that are very important to your forge, heat treat and testing vendors. Partner with your suppliers The most critical way to ensure your component gets accurately certified is to flow down your ABS requirements to your suppliers and your entire supply chain. Throughout the supply chain, providing precise requirements ensures that your component is manufactured under the Rules without delays or added costs. Often, by the time companies submit the purchase order to raw material vendors, the ABS Rule requirements are missing. This problem can easily be avoided if the requirements flow down the supply chain during quoting. An ideal request for quote and purchase order packet includes all the drawing and specification requirements and ABS Rules that apply. Your supplier can work with you to see that the Rule requirements are enforced during the manufacturing process, eliminating time-consuming errors and reducing inspection costs. Use an approved ABS Supplier Using ABS-certified suppliers can further minimize the cost and lead-time of inspections. For example, if you need a forging where final heat treatment, testing and inspection will occur at another level within the supply chain, and the forging facility is an ABS-approved supplier, ABS certification may not require a forge-level inspection. This is why working with experienced, approved suppliers will save time and money; they can help you determine when an inspector must present during operations and help you meet all requirements. The Scot Forge Advantage At Scot Forge, we are uniquely qualified to provide you with ABS-certified products and materials. We are one of the few U.S. companies that have been audited by the American Bureau of Shipping and approved as a worldwide ABS forging supplier for ABS and Non-ABS grades up to 80,000 lbs. at Scot Forge and 270,000 lbs. at our joint venture, NAF.  Our technically trained sales staff has extensive experience quoting ABS-certified products. We partner with you to see that your part meets all the requirements to gain certification while minimizing time and costs.    Scot Forge custom manufacturers open die forgings and seamless rolled rings with the capability to forge parts up to 100,000 lbs. and roll rings up to 252" in diameter. From gearbox repair to broken rudder stock, we can assist you with your marine part, get you out of the dry dock and back in commission!   Contact us to speak with an expert at Scot Forge to learn more.

Overall, the use of forgings in both nuclear fusion and fission reactors is critical for ensuring these devices' safe and efficient operation. Forgings play a crucial role in both nuclear fusion and fission. In nuclear fusion, forgings are used to construct the components of fusion reactors, which are designed to harness the energy released by the fusion of light elements. The walls and components of a fusion reactor must withstand the high temperatures and pressures generated by the fusion process and the corrosive environment created by the intense radiation and high-energy particles produced by the reaction. Forgings made of high-strength, corrosion-resistant materials, such as superalloys and refractory metals, are commonly used to build these components, as they can withstand the harsh conditions inside the reactor.  Forgings also play a key role in the design and construction of the magnetic confinement systems that are used to contain the plasma and prevent it from coming into contact with the reactor walls. These magnetic confinement systems are designed to generate powerful magnetic fields that can confine the plasma, keeping it stable and controlled. Forgings made of high-strength, magnetically-conductive materials, such as copper and niobium-titanium, are used to construct the coils that generate these magnetic fields. In addition, using forgings in these systems helps ensure that the components are durable, efficient, and able to withstand the intense conditions inside the reactor.  In nuclear fission, forgings are used to construct the components of fission reactors, which are designed to generate electricity by harnessing the energy released by the fission of heavy elements, such as uranium and plutonium. The components of a fission reactor must withstand the high temperatures and radiation produced by the fission process and the corrosive environment created by the intense heat and radiation. Forgings made of high-strength, corrosion-resistant materials, such as stainless steel and refractory metals, are commonly used to build these components, as they can withstand the harsh conditions inside the reactor.  Forgings also play a crucial role in the design and construction of the control rods that are used to regulate the rate of fission in a reactor. These control rods, made of neutron-absorbing materials such as boron and cadmium, are inserted into the reactor core to absorb excess neutrons and control the rate of fission. Forgings are used to make the control rod assemblies, which must be strong enough to withstand the intense conditions inside the reactor, as well as precise and precise enough to accurately control the rate of fission. In addition, the use of forgings in these assemblies helps to ensure that the control rods are durable, efficient, and able to perform their critical safety function.  Overall, the use of forgings in both nuclear fusion and fission reactors is critical for ensuring the safe and efficient operation of these devices. The high-strength, corrosion-resistant, and magnetically-conductive properties of forgings make them ideal for use in these reactors' harsh environments and help ensure that the components and systems can perform their intended functions effectively. So, whether you are designing the latest small modular reactor or looking to pursue R&D experiments, call us to discuss how forgings can support your most critical applications.

Scot Forge reviews the numerous applications in forgings and the different methods for testing. Forging is one of the oldest skills known to man and it’s tough to envision manufacturing and even life without the parts created by forging. Some of the applications for forgings can be straightforward, such as rings for gears and flanges or bars for ship shafts. In contrast, others are very complex, such as hollows for oil country tubular goods (OCTG) and pressure tubing for power boilers or domes for nuclear waste storage. There are numerous applications for forgings. As a result, there are many manufacturing and testing standards that forgings must meet. Forgings are commonly created to the standards of the following organizations: •  AISI - American Iron and Steel Institute • ANSI - American National Standards Institute • AMS - Aerospace Material Standards • API - American Petroleum Institute • ASTM - American Society for Testing and Materials • ASME - American Society of Mechanical Engineers • NAVSEA - Naval Sea Systems Command • DIN EN - European National Standards And, just like the applications of the forgings, the methods for testing can be varied. For instance, testing from a ring to a tube for a critical, high-pressure use is not as simple as it first appears. Numerous standards could apply; it depends on the application. ASTM A668, for example, references six different standards. A275/A275M Practice for Magnetic Particle Examination of Steel Forgings A370 Test Methods and Definitions for Mechanical Testing of Steel Products A388/A388M Practice for Ultrasonic Examination of Steel Forgings A788/A788M Specification for Steel Forgings, General Requirements E290 Test Methods for Bend Testing of Material for Ductility E340 Practice for Macroetching Metals and Alloys Each standard specifies procedures for measurements or test methods. As far as material standards, the mill typically calls out the capabilities of material based on sound forging practices. There are many tests available to meet criteria standards and ensure part quality that helps find indications, or imperfections, in the material – magnetic particle test (MT), dye penetrant test (PT) and ultrasonic inspection (UT). MT and PT discover surface flaws; they are relatively easy and inexpensive. MT uses a magnetic field with a solution containing iron filing particles that highlight an indication in the forging as the iron particles collect at the magnetic flux that leaks from a crack or void. PT can be more time consuming as it requires applying a liquid penetrant to the forging and then removing it; a developer must then sit on the piece to draw out remaining penetrant from any cracks or crevices. UT is a volumetric test and uses sound waves to find gaps in the forging; when the sound wave hits a void, it ends back a spike in the ultrasonic display, which is called an indication. All these methods require a finished surface to allow for accurate readings. Performing a test is one process, but evaluating a forging to determine if it is acceptable is a different process altogether. For instance, it’s not uncommon to require a UT inspection by requesting “UT per ASTM A388.” The problem, spelled out in this document, is that “this practice is intended for application to forgings, with a wide variety of sizes, shapes, compositions, melting processes, and applications. It is, therefore, impracticable to specify an ultrasonic quality level which would be universally applicable to such a diversity of products.” The standard does not list exact acceptance requirements other than indications that cannot exceed an acceptable size. Since metal transitions from a liquid to a solid, there are always some particles that get trapped, much like air bubbles or dirt would in ice. While most particles get eliminated during the forging process, some could remain at an acceptable level. So, this is why it is essential to discuss acceptance criteria, list the voids or flaws that might be found as well as the limits or extent that they are permitted. A good example is specifying the amount of non-metallic inclusions that may be permitted. The specification would include the sizes and spacing between non-metallic inclusions that must be measured and evaluated, which helps set expectations for both the customer and the manufacturer. It is important to note that there are ways to reduce the risk of indications in a forging, such as using refined material like Vacuum Arc Remelt (VAR), but increased purity results in increased cost.  Finding the balance between acceptable quality and cost-effectiveness is often tricky. Not to mention how the acceptance criteria vary by each forged product. So, it is essential to carefully review documents that support the requirements of the end-use application. From the simple to the complex, a partner like the Scot Forge employee-owners can help guide you through this process.

Scot Forge discusses hot rolled bar vs cold rolled bar, and forged bar processes to find the right solution for any application. Call today! In the world of bar products, there are different ways to manufacture bars and some different things to consider when purchasing bar. Often lead time, quantity, and quality are what drive decisions when purchasing bar . The end-use application can also play a significant role and can range from a product that utilizes the full length of a 20-foot bar to portions of the bar cut and machined to a unique geometry. In this blog, we discuss the options that can provide both high and low quantity options for buyers - Hot Rolled Bar, Cold Rolled Bar, and Forged Bar. (Please note - There is another process which pushes molten bar through a die called hot-drawing or extruding. This method is not ideal for low quantity purchases.) So, Hot Rolled vs Cold Rolled and Forged Bar Rolling and forging bar boils down to the same fundamental process of reducing the thickness or changing the cross-sectional area of metal by compressive forces. In other words, a large piece of metal known as a billet is pressed down to the size, shape, and length required for a project. This process not only gives the bar shape, but it also adds properties of strength to the bar.  What is Hot Rolled Bar? This is the process of heating a billet to more than 1000 degrees Fahrenheit, above the recrystallizing phase of metal so that it’s workable, then rolling it through a planishing mill or rollers to give it its shape. Heating the metal is vital because changing the molecular structure of the metal form dendrites (thread-like sporadic structures) to grains (organized block-like structures), which only happens when metal is in a malleable state. The creation of stronger metal is not only due to the formation of the grains, but the directional grain flow achieved when the bar is rolled. Pros & Cons Hot Rolled Bar Hot rolled bar is quick and creates single or multiple pieces easily. Unfortunately, where hot rolled bar falls short is with dimensional tolerances. When the metal cools, it contracts and that leads to the likelihood of warping, areas of varied thickness, and a scaled finish, which means machining is required if dimensional precision or finish type is essential. Lastly, with hot rolled bar, timing is everything. If the rolling cycle is missed lead time is drawn out since additional bar wouldn’t be produced until the next mill progression. What is Cold Rolled Bar? This process takes everything we just discussed about Hot Rolled Bar and adds a step. When the bar reaches near-room temperature, it is drawn through dies or rerolled in a progressive rolling process. This additional step inherently adds strain hardening to the bar because it is worked after recrystallization. Strain hardening can only harden the metal so much, the bulk of hardening is achieved during the molecular restructuring provided by hot rolling, depending on the grade.   Pros & Cons Cold Rolled Bar Cold rolled bar has better dimensions, straightness, and increased yield strength. It, again, is used for single or multiple piece requirements. But, with the extra step or rerolling, cold rolled bar is time-consuming and can extend lead times. Unlike a hot rolled bar, however, additional machining for precision isn't required, and the finish is not as scaled. What is Forged Bar? This process, like a hot rolled bar, takes a billet and heats it until it is malleable. This is where the processes differ, rather than rolling the bar to get it to size, forging either hammers or presses the bar to the rough dimensions required. The operation gives the bar a 3:1 reduction ratio minimum, which means that the grain sizes are much smaller and tighter in a forged bar, and it consolidates the centers if there are any piping issues. Then, depending on the diameter of the bar, the bar is put through a planishing mill giving it a smooth, rounded surface.   Pros & Cons Forged Bar Forged bar process takes the best of hot rolled and cold rolled bar and achieves it quickly and efficiently. These bars maintain dimensions and straightness as they cool while having an even higher yield strength because of forgings' unique capability of producing sound-centers during the forging step. The 3:1 minimum reduction helps eliminate any centerline non-consolidation issues that affect bar quality. Unlike the additional step in cold rolling, the extra step of rolling after forging is done while the bar is hot, so there is no time wasted on additional processes after cooling. Forged bar can be used for single or multiple piece requirements and produced on demand. The other significant advantage is for large diameters. The rolled bar is produced to a specific maximum size where the forged bar has a broader span of diameter capabilities.    If you are new to forging or want to compare bar quality, the Scot Forge Bar Team is here to help you navigate your options. Contact our Scot Forge Bar Team for more information about forged bar. Forging may not always be the best option for your project, and if that is the case, we are happy to point you in the direction of vendors we know and trust.

Director of the Office of Trade and Manufacturing Policy in the Trump administration the Secretary of the US Navy, visited North American Forgemasters Steel Forging Complex to inspect the manufacture of shafting and other forgings that form vital components for US Navy vessels. DR. PETER NAVARRO AND NAVY SECRETARY RICHARD SPENCER VISIT NORTH AMERICAN FORGEMASTERS STEEL FORGING COMPLEX, NEW CASTLE, PA. New Castle, PA – October 10, 2019 – Dr. Peter Navarro, Director of the Office of Trade and Manufacturing Policy in the Trump administration, and Richard Spencer, Secretary of the US Navy, visited an area steel mill today to inspect the manufacture of shafting and other forgings that form vital components for US Navy vessels.  They were accompanied by Congressman Mike Kelly, whose congressional district (PA-16) includes New Castle.  Kelly had suggested the visit to the New Castle plant to Navarro and Spencer. They viewed the production of a 72’ foot-long, 190,000 lb. main propulsion shaft for a Virginia Class attack submarine as it was forged—red hot-- under a 10,120-ton capacity forging press at 2,300 degrees Fahrenheit. Other Navy shafts in production in the plant were also on view, including forgings for the Navy’s Arleigh Burke-class destroyer.    The facility is equipped to make large forgings for all of the Navy’s ships and submarines, including aircraft carriers.  Such forgings include also critical parts for the nuclear reactors that supply power to submarines and aircraft carriers.   North American Forgemasters is a joint venture between ELLWOOD, Ellwood City, PA and Scot Forge, Spring Grove, IL.  Executives of those companies were on hand to host the Washington visitors.  David Barensfeld, Chairman of the Board of ELLWOOD, stated: “We are thrilled to receive these important visitors from the Navy and the White House.  Their personal attention to our nation’s industrial supply base is proof of their strong engagement in the successful build-up of our nation’s defense.”    John Cain, Chief Executive of Scot Forge, commented: “North American Forgemasters represents a $100 million dollar investment by Scot and ELLWOOD in the industrial infrastructure necessary for our national defense, on top of the large additional capital investment the two partners have made in their plants to finish parts forged at NAF.  We need for the Navy to require that critical parts such as propulsion shafts be subject to a strict Buy American rule that keeps American shops like NAF familiar, ready and able to make these important parts.” Barensfeld and Cain stressed that North American Forgemasters is also able to make nuclear power supply parts for Navy ships, including parts for their nuclear reactor-fired power, and anticipates receiving orders for these parts from Navy subcontractors.  They stated: “We cordially invite procurement officials from the Navy and its contractors to visit NAF as well as our other plants in western Pennsylvania and Illinois to view other investments our two companies have made to be able to manufacture the Navy parts, and to discuss how we can collaborate on the design and production of critical parts, to better save the Navy time and money in their procurement.”    Under the joint venture agreement, ELLWOOD supplies steel ingots to the joint venture, which forges the parts to a semi-finished shape for further forging and/or machining at the partners’ respective plants in New Castle, Irvine, PA and Spring Grove, IL.   The North American Forgemasters plant is located in New Castle, adjacent to ELLWOOD’s electric arc furnace shop, ELLWOOD Quality Steels, that supplies NAF with its raw material for forging.  Barensfeld stated, “We thank Congressman Kelly for suggesting today’s visit, and for his steadfast support of a strong American defense force, and in particular for his outspoken support for a strong Buy American rule requiring that critical defense parts be made in the United States and not imported from foreign companies.” About ELLWOOD Since our founding in 1910, ELLWOOD has grown organically and via acquisition to become the leading vertically-integrated supplier of quality metals and custom-engineered components for critical applications worldwide. 100% American-owned and made, from raw materials through finished machined and coated products ready for assembly, we provide the products our customers require in the world’s most demanding applications, including those supporting our nation’s defense. While our footprint now spans 30 locations across North America, we haven’t lost sight of what’s right: treating our more than 2,100 team members, industry partners and customers like family. As a family-owned business, we work as a committed partner with our stakeholders to ensure integrity, welcome new ideas, and achieve shared success. About SCOT FORGE Starting as a small hammer shop in Chicago in 1893, Scot Forge is proud to be a 100% employee-owned American manufacturer. Based in Spring Grove, Illinois, U.S.A, Scot Forge is a company with a 126-year track record of success focused on solving our customers’ greatest challenges. With five U.S. facilities and 500 employee-owners, Scot Forge offers the most modern open-die and rolled-ring forging, machining and downstream capabilities in North America. From the wheels of NASA's Curiosity Mars Rover, to mission-critical components for nuclear submarines, to large hydraulic cylinders for the largest mining trucks on the planet, Scot Forge creates the precision forged metal parts used in demanding applications all over the world.