3 Uses of Seamless Rolled Ring Forging

Seamless rolled ring forging is superior to the other methods of producing ring structures from metal. Seamless rolled ring forging creates stronger ring shapes because they gain circumferential grain structures. Whether this occurs through a ring rolling mill or via an open die forging using forging hammers, the result is the same round, extremely durable, seamless rings that may not even need to be machined after the forging is complete.

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The Alternatives to Seamless Rolled Ring Forging

Because seamless rolled ring forging is more expensive, some manufacturers go a less expensive route and cut the metal plate, roll it into a ring, and then weld it together. Another option commonly used is casting the parts. These might work for some low-end applications, but if the ring is under tremendous pressure or subject to a corrosive environment, it will not work as well as a rolled ring forging, and may even be a point of failure where it is used.

Aviation

There are few industries that put as much physical stress on their parts as the aviation industry. The parts in aircraft are under almost constant stress from air pressure changes, high-velocity rotation, and just the simple stress caused by the physics of flight. Not to mention that a mechanical failure at 20,000 feet can be catastrophic. This is one of the reasons why the aviation industry uses seamless forged rolled rings in major components in jet engines, jet turbines, and helicopter gearboxes. Another benefit of forged rolled rings is that they are (on average 33%) stronger than cast or welded parts and 5 to 10% lighter.

Automotive

In the automotive industry, forged seamless rolled rings are used in almost every major structural or high-load component in trucks and automobiles. Crankshafts, camshafts, clutches, braking systems, gears, and couplings are just a few of the ways that forged rolled rings are used. Forged parts not only handle wear and tear of constant, daily use better, but also lighter and more resistant to torque and high pressure.

Oil and Gas Production

Seamless rolled rings are best known for their uses in oil and gas production where they are used as rings for pipe connectors and also used for many different types of flanges and pressure vessel connections for pipelines. Other uses of seamless rolled rings include hydraulic fracturing (fracking), subsea connections, and surface gas and oil exploration. The ability to withstand high pressure, high temperatures, and corrosive substances and the potential for harm to people or the environment makes the use of forged rolled rings especially important since connections are typical points of failure in this system.

Where Are You Getting Your Seamless Rolled Ring Forging?

Our forging experts are capable of creating the strongest, most reliable seamless rolled rings. When dealing with a forged rings manufacturer, it is important to buy only from reputable companies that have the skill, experience and products you require. We provide a complete line of rolled ring forgings, industrial forged flanges, and nozzles for the oil, gas, and petrochemical industries. For more information, call us at (281) 441- or contact us online to get a quote from our sales staff.

Seamless Rolled Rings

Philadelphia Forgings is a preferred supplier of seamless rolled rings and other superior forgings. Serving customers in Pennsylvania, New Jersey, Delaware, and across the nation, Philadelphia Forgings offers seamless rolled rings with enhanced densities and aligned grain flow. The weights of these seamless rolled ring forgings range from a few pounds to thousands of pounds while sizes range from two inches inside diameter (I.D.) to twenty feet outside diameter (O.D.).

The Rolled Ring Forging Process

The process of rolling seamless rings begins with open die forging which creates a preform workpiece. Open die forging processes, rounds, and upsets a piece of stock which aligns the grain flow of the metal. The workpiece is then punched in the center to create a hole necessary to place the workpiece in the ring mill.

The ring mill uses three different types of rolls: a driver roll, an idler roll, and two axial rolls. The idler roll rotates and applies pressure to the inside of the ring while the driver roll applies pressure to the outside of the ring. The metal begins to flatten and the diameter increases; the height of the ring, meanwhile, is controlled by the two axial rolls. The ring rolling process continues until the correct diameter is met.

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Benefits of Seamless Rolled Ring Forgings

The open die forging process removes structural defects as well as porosity and aligns the grain flow in the preform workpiece. The rolling process itself creates rings with improved concentricity and smoothness. Furthermore, ring forgings that have been created in rolling mills are more cost effective. Companies who order our seamless rolled rings do not need to burn or machine out the inside diameter as is the case with plate products. With higher impact and fatigue resistance as well as a more predictable grain structure, seamless rolled rings offer the greater strengths and better mechanical properties that many manufacturers need.

Seamless Rolled Ring Forging Materials

Rolled rings are forged from many materials including stainless steel, carbon steel, alloy steel, aluminum alloy, brass alloy, titanium alloy, nickel alloys, copper, and many others. These forgings can meet nearly any strength requirement, whether for stress, impact, or load. Visit the forged materials section to see a full listing.

July 3,

Have you always wondered about how rolled ring forgings are produced or the difference between open die forgings and seamless rolled ring forging? If so, let’s explore the differences between these two types of forging processes.

What is Open Die Forging?

Open die forging that is sometimes called free forging refers to the process that involves a piece of metal that’s being deformed between multiple dies that don’t enclose the material entirely. In other words, it got its name because of the fact that the metal that’s being used is free and is not completely confined by impression dies that restrict its form. Due to the nature of its production process, open die forging allows for a wide range of shapes and sizes. In fact, it is capable of forming forgings that are only a few pounds heavy to massive 150-ton pieces.

What is Seamless Rolled Ring Forging?

Seamless rolled ring forging starts with a circular preform made out our metal that’s been pierced in the middle in order to form a hollow shape that looks like a doughnut. To increase its diameter or lessen the thickness of its walls, this ring is rotated as heat is being applied to it. Rolled ring forgings that are created through this process are known to be sturdier and more reliable compared to other parts. They also feature better heat tolerance and users can be certain of the maximum heat that these rolled ring forgings are able to withstand. Most importantly, they’re also manufactured at a lower cost than other comparable products since less machining is required.

Looking for Rolled Ring Forgings?

Ferralloy, Inc. supplies rolled ring forgings in diameters up to 110” from alloy, carbon, and stainless steel. Contact us today to request a quote.

At Scot Forge, we produce seamless rolled rings using an open die forging method or our ring rolling mill. Forged seamless rings are incredibly durable and reliable because they have inherent, circumferential grain structures and no weldments, eliminating weak points. Our seamless ring rolling mill is also a more cost-effective forging process than other methods because less starting stock is required to manufacture the ring. As a result, there is less material to machine away from the end product, another added benefit. When combined with a ring expander, ring rolling generates exceptionally round and durable ring products in any forgeable material.

The seamless rolled ring forging process starts with heating a pre-cut billet, then the malleable metal is placed on a hammer or press. The ring shape begins with a centerpiece "snapped" from the pre-form to produce a hollow center, similar to a donut, and moved to the ring mill.  Once on the ring mill, the center of the part supported by a mandril and rollers apply pressure from different angles to gradually expand the ring.  Rings made on a press are placed on a pin, supported by a saddle, then rotated as force is applied to expand the opening. Both techniques create circumferential grain flow creating the desired dimensions of the forged ring.