The present invention discloses a process of manufacturing forged components using a combination of open die and closed die forging, and machining. The process involves the steps of cogging of the ingot, upsetting the cogged bloom in two steps to form a preform, closed forging the preform on a hammer, rough machining, heat treatment, semi-finishing, and finally finishing the component. The present invention is applicable to any forged components that are used in variety of industries, particularly those which are formed from large ingots. The invention is particularly useful for safety- and application-critical components such as a fluid end which is used in oil and gas industry. With the process of the present invention, 55 to 60% of the shape and size of the final component is achieved through forging and remaining 40 to 45% through machining. Incorporating the closed die forging stage in between open die forging and machining stages of the results in about 27% material reduction and over 60% reduction in machining time.

The present invention discloses a process of manufacturing forged components using a combination of open die and closed die forging, and machining. The process involves the steps of cogging of the ingot, upsetting the cogged bloom in two steps to form a preform, closed forging the preform on a hammer, rough machining, heat treatment, semi-finishing, and finally finishing the component. The present invention is applicable to any forged components that are used in variety of industries, particularly those which are formed from large ingots. The invention is particularly useful for safety- and application-critical components such as a fluid end which is used in oil and gas industry. With the process of the present invention, 55 to 60% of the shape and size of the final component is achieved through forging and remaining 40 to 45% through machining. Incorporating the closed die forging stage in between open die forging and machining stages of the results in about 27% material reduction and over 60% reduction in machining time.

A method of manufacturing an annular material includes: a forging process of making a discoid forged material by forging an alloy material; and a ring rolling process of making an annular material by performing ring rolling on an annular intermediate made by forming a through-hole in the forged material. In the forging process, hot forging which achieves an absolute value 1 of a strain in a circumferential direction of the forged material that is greater than or equal to 0.3, an absolute value h of a strain in a height direction of the forged material that is greater than or equal to 0.3, and a ratio h/1 between the absolute values of the strains that is in a range of 0.4 to 2.5 is performed at least two or more times.

The present invention provides an austenite-ferrite stainless steel. The steel composition contains in % by weight: 0.01%C0.10% 20.0%Cr24.0% 1.0%Ni3.0% 0.12%N0.20% 0.5%Mn2.0% 1.6%Cu3.0% 0.05%Mo1.0% W0.15% 0.05%Mo+W/21.0% 0.2%Si1.5% Al0.05% V0.5% Nb0.5% Ti0.5% B0.003% Co0.5% REM0.1% Ca0.03% Mg0.1% Se0.005% O0.01% S0.030% P0.040% the rest being iron and impurities resulting from the production and the microstructure being composed of austenite and 35 to 65% ferrite by volume, the composition furthermore obeying the following relations:
40IF65
with
IF=10% Cr+5.1% Mo+1.4% Mn+24.3% Si+35% Nb+71.5% Ti595.4% C245.1% N9.3% Ni3.3% Cu99.8
and
IRCGCU32.0
with
IRCGCU=% Cr+3.3% Mo+2% Cu+16% N+2.6% Ni0.7% Mn
and
0IU6.0
with
IU=3% Ni+% Cu+% Mn100% C25% N2(% Cr+% Si)6% Mo+45 as well as a method of manufacture of plates, bands, coils, bars, wires, profiles, forged pieces and molded pieces of this steel.

A method for producing a high-strength magnesium alloy material includes (a) a step of preparing a magnesium alloy workpiece having a top face and a side face; and (b) a step of applying a compressive load p (MPa) from the top face side of the workpiece and performing a uniaxial forging process on the workpiece. Step (b) is performed while suppressing deformation of the workpiece widening outward and under conditions including (i) p>f (where f is the compressive breaking stress (MPa) of the workpiece); (ii) a plastic deformation rate is less than or equal to 10%, and (iii) a strain rate is less than or equal to 0.1/sec.

A method for producing a high-strength magnesium alloy material includes (a) a step of preparing a magnesium alloy workpiece having a top face and a side face; and (b) a step of applying a compressive load p (MPa) from the top face side of the workpiece and performing a uniaxial forging process on the workpiece. Step (b) is performed while suppressing deformation of the workpiece widening outward and under conditions including (i) p>f (where f is the compressive breaking stress (MPa) of the workpiece); (ii) a plastic deformation rate is less than or equal to 10%, and (iii) a strain rate is less than or equal to 0.1/sec.

A method for manufacturing a forging includes forming a bi-material billet by enclosing a core material other than steel in a steel cylinder with a cylindrical wall and steel end caps. The cylindrical wall is heated. The method includes a first forging blow on the heated billet or on a disk-shaped rough forging forged from the heated billet with a first closed blocker die to produce a forging preform, and a second forging blow on the preform with a second closed blocker die to produce a netshape forging. An evacuation hole is formed in a steel shell of the netshape forging and the core material is removed from the netshape forging via the hole. At least 85 percent of the core material is in a liquid phase during the first and second forging blows, and removal of the core material.

A method for manufacturing a hot-forged member includes heating an unheated material for hot forging in a furnace to a hot forging temperature; bonding a heat-resistant insulation material to at least a part of a surface of a material for forging removed from the furnace to obtain a material to be hot forged; and compressing a part or all of the material to be hot forged into a predetermined shape using any of a die, an anvil, and a tool.

A method for manufacturing a hot-forged member includes heating an unheated material for hot forging in a furnace to a hot forging temperature; bonding a heat-resistant insulation material to at least a part of a surface of a material for forging removed from the furnace to obtain a material to be hot forged; and compressing a part or all of the material to be hot forged into a predetermined shape using any of a die, an anvil, and a tool.

A method for monitoring and controlling open die forging processes, includes: a) calculating the geometry evolution of a workpiece during open die forging using empirical models; b) in parallel with step a), that is to say at the same time or at least partially overlapping times as step a), calculating the workpiece temperature across the cross-section of the forged workpiece; c) calculating the distribution of the change in shape over the length of the workpiece, preferably by using the geometry evolution calculated in step a); and d) manually or automatically controlling the distribution of the change in shape in a predefined region on the basis of the distribution of the change in shape calculated in step c).