:UQ. Proceedings. 14th International Forgemasters Meeting. Wiesbaden, Germany, September 3 to 8, 2000

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1 :UQ 14th International Forgemasters Meeting Wiesbaden, Germany, September 3 to 8, 2000 Proceedings UB/TIB Hannover Verein Deutscher Eisenhuttenleute (VDEh) German Iron and Steel Institute

2 The Rohre Stangen Schmiedestucke Contents of Proceedings Welcome Dieter Ameling N.N.; Representative of Hessia or of Wiesbaden Contoured forging of compressor and 47 turbine wheels Martin Franzke, Wojciech Harabasz, Gerald Stein Plenary Recent trends and technical developments 1 in the heavy, opendie forging industry in Japan Takashi Fukuda, Norio Morisada Recent trends of the forging industry 9 in Korea JeongT. Kim, HeeS. Chang, JongY. Kim Forging industry in Poland 13 Robert Szyndler Forging developments in North America 15 James F. McKinley Recent developments in the open forging industry in Austria, Germany, Sweden and Switzerland Open Die Forging Industry associated with the German Iron and Steel Institute Oliver Durr, Arno Frank, Waiter Grimm, Reiner Kopp, Reinhard Schmidt, HansJoachim Wieland die 23 Alternative methods for cold expansion of 55 rings and tubes Gerald Stein, Heinrich Feichtinger The system of forging processes and 63 development of material working by pressure Yury Anatolyevich Zimin Forging design and manufacturing process 65 of integral type closure head for reactor vessel Michio Kiguchi, Kazuhito Tani, Toshiya Moriyama, Yshiakai Susuki, Eiichi Oku, Kazuhiro Nakamura 73, Manufacture of a shaft with flange using the upsetter Hideki Takamori, Yoshiaki Suzuki, Takaya Kawai, Hiroaki Matsubara, Osamu Matsumoto, Hiroshi Takahara, Takahiro Nakada New capabilities of forging with the use of 79 radial forging machines Valery A. Tiurin, Vladimir V. Ovechkin Efficiency in application of macroshear 83 strains by forging Valery A. Tiurin, Vladimir V. Ovechkin Metal Forming The production of safety critical forgings for pressure vessel applications" Dr. Paul Bates Key forging technique of heavy forgings Liu Zhubai, Li Weimin, Deng Dongmei, Zhou Weizhi, Liu Yubo, Li Jinke Programforgingprocess on the 55 MN 87 open die forging press at Edelstahlwerke Buderus AG, Wetzlar/Germany Volker Schneider Axial closeddie rolling a technological 91 alternative being in hard competition in the field of industrial metal forming Jurgen Husmann Enpar Bleche Teile nach Zeichnung Flanschen Sonderwerkstoffe GmbH Betriebsweg Gummersbach Tel /79 80 Fax / aus Sonderlegierungen und Sonderstahlen, Titan und Titanlegierungen, Nickel und Nickellegierungen, Zirkonium, Tantal, Niob fur die chem. Industrie und den Anlagenbau, Luft u. Raumfahrt

3 "C3 I ft CD Dynamic order planing in mechanical 99 production taking account of the entire production chain Manfred Becker, Ralf Rech Plant Engineering Installation of an 8/16t vacuum induction 104 furnace at Saarschmiede H. Wagner, N. Blaes, W. Ottmar, R. Heck Manufacture of large forging ingots by 109 advanced ESR processes U. Biebricher, A. Choudhury H. Scholz, R. Schumann lis ft If pke *" i< I Warn' m len 'ejiarbeitung 1* ' CD 1 1 Design and operation of a 25 t VIM 114 (VacuumlnductionMelting Furnace) and a t press for melting and forging of typical nickelbase alloys like 718 and (Wst.Nr ) and 706 Tom Witheford, Art Kracke, Uwe Schneider The description and performance of oxyfuel... forge preheat furnaces at North American Forgemasters Marvin W. Puth, William P. Edwards, Andrew Kiesler 117 Optimisation of the Quality level of open 126 dieforgings by the introduction of modern, innovative forging technology D. Bokelmann, J. Poppenhager, U. Spies, H. Wagner Computerised optimisation of the forging 132 on a 3300 tons open die forging press Chnstoph Heischeid, Helmut Betz, Rainer Dango In 111 SHE* i^rtner (fd Steuerungen frf unserer IS m Serienplbau. t* *«* 1^ *** ft\e<v ft* D Hattersheim Tel: FOX: Upgrading of forging furnaces, new 137 technologies to reduce operating costs, material loss and environmental pollution Reinhard Schmidt, Wolfgang Bender, Stefan W. Metz GFM radial forging design development 145 Rupert Wieser, Robert Koppensteiner Water powered 2250 tonnes opendie 151 forging press upgrade with an "Oilgear forge valve" system design JeanFrangois Magnani, Derek Kinsey Drives of hydraulic presses 157 M. Pahnke New developments in high pressure 160 hydro mechanical descaling Dipl Ing Dirk Kern Experiences with hydraulic forging machines 164 from SMS Meer Christian Meybohm, Paul Nieschwitz, Peter Dreinhoff

4 a production Improving Properties by Process Technique Black or white? That is the question, Manufacturing technology and mechanical 171 properties of the monoblock lowpressure rotor forgings JeongT Kim, MeyoungR. Lee, HeeK Kwon, HeeS. Chang, JinK. Kim, InJ. Yu Problems of quality assurance of forged 177 heavy plates Ladislav Jilek, Svatopluk Burda, Bohus Dvorak, Karel Matocha, Jin Brus, Optimisation of the heat treatment of 183 improve the mechanical properties of heavy forgings Pierre Bocquet, Isabelle Poitrault, Jean Pisseloup, Rene Dumont, Elisabeth Massoni, Sabine Denis Experiences in the use of polymer solutions... for hardening of forged alloyed tool steels Markus Jutten, KarlErich Piper 191 Combination of cold and hot forging in a 199 single forming step technique, workpiece geometriesm, material characteristics Ursula Weidig, Kursad Kayaturk, Ahmet Kurt, Kurt Steinhoff, Erman Tekkaya Just ask us, A review of hydrogen flaking and its 207 prevention response John E. Steiner, Robert D, Williams If you need reliable solutions to your application engi neering problems, FUCHS LUBRITECH is your partner Take forging technology: LUBRODAL F 20 C and LUBRO DAL F 318 N are two forging lubricants specially desi gned for hot forging. LUBRODAL F 24 W is a perfect warm forging lubricant. With or without graphite, black or white: the excellent characteristics of LUBRODAL products fulfil the most stringent requirements. LUBRODAL is watersoluble, environmentally harmless and physiologically safe. LUBRODAL protects tools their life and machinery and prolongs The high quality of FUCHS LUBRITECH lubricants is based on experience, advanced technologies an product refinement. Go ahead and contact us, if you want more information on FUCHS LUBRITECH's LUdR(DDAl_ line of forming lubricants. Properties of Forged Steels Creep properties and microstructural 215 evolution of 2 1/4Cr1Mo1/4V and 3Cr1MoV modified steels for pressure vessel forged components Augusto Di Gianfrancesco, Oriana Tassa, Angelo Finali, Lino Callegari Life calculation of creep loaded notched 221 parts with different geometries Tong Sheng Mao, Joachim Granacher, Christina Berger Mechanical and metallurgical properties 228 of CrMo steels for the petrochemical pressure vessel JeongT Kim, ByungH. Kim Application of high strength MnMoNi steel 234 to pressure vessels for nuclear power plant Komei Suzuki, Iku Kurihara, Tomoharu Sasaki, Yasuhiko Tanaka, Yoichi Koyama FUCHS LUBRITECH GMBH HdnsRcmerStr 713 D67685 Weilerbach Phone ++49(0)6374/9 245 Fax ++49(0)63 74/ Emdil de http//wwwfuchslubntech de Low alloyed Steels The potential of the European 2% CrMoNiWV rotor forging material for power plant application TorstenUlf Kern, KarlHeinz Schonfeld Michael Brandle,

5 The effect of gashing and tempering para 250 meters on FATT of 2%CrMoNiWV alloy steel rotor forgings Michael P. Manning, KarlHeinz Schonfeld, Steam turbine shafts of combined high 255 pressure / low pressure rotors C. Gerdes, H. Bartsch Alloy and process development to improve 262 inservice performance of forged back up rolls and sleeves used in P. Noak, Paul Bates cold mills High Temperature Steam Rotor Steels.. Development and qualification of rotor steels for 600 to 650 C application in COST 501 / COST 522 TorstenUlf Kern, Horst Cerjak, KarlHeinz Mayer, Marc Staubli, Rod Vanstone, Gunther Zeiler, KarlHeinz Schonfeld 270 Longterm investigations on specimens of production rotors manufactured of the advanced martensitic 10% Crsteels X12CrMo(W)VNbN10 1 (1) K.H. Mayer, T.U. Kern, K.H. Schdnfeid, M. Staubli, E. Tolksdorf Effect of boron on creep strengthening 12% Cr heat resistant steel Tsukasa Azuma, Kazuhiro Miki, in 283 Yasuhiko Tanaka Thermal processes add value Recent developments in 9 to 12 chromium 290 steel open die forgings for steam and gas turbine applications at Bonier Wilfried Meyer, Gunther Zeiler, Robert Bauer Manufacturing of 12%Cr rotor forgings 295 for high temparature steam turbines from electro slag hot topped ingot Masato Mikami, Koji Morinaka, Yoshihiro Okamura, Satoshi Tanimoto, Yasushi Wakeshima, Ryutaro Magoshi, Yoshikuni Kadoya, Asaharu Matsuo Development and manufacturing of next 301 generation of advanced 12% Cr steel rotor for 630 C steam temperature Yasunon Kagawa, Fumihiko Tamura, Osamu Ishiyama, Osamu Matsumoto, Takemitsu Honjo, Tomohiro Tsuchiyama, Yoichiro Manabe, Yoshikuni Kadoya, Ryotaro Magoshi, Hisataka Kawai Development and trial manufacturing of 309 9%CrMoNiVNb steel for combined high pressure and low pressure rotor forgings Masato Mikami, Koji Morinaka, Kazuhiro Nakata, Kihei Soeda, Yoshikuni Kadoya, Ryutaro Magoshi, Hisataka Kawai, Asaharu Matsuo High nitrogen steels for aviation and aero 317 space applications Irina Hucklenbroich, Gerald Stein The LOI Group has the plant engineering experience and process engineering innovation capabilities needed for effective support, together with a worldwide service network Our heat treatment systems for forged parts show our expertise in enhancing quality at the same time as improving economics We offer tried and tested plants and proven control systems for all types of heat treatment processes only to excellence in We are committed not plant engineering but also to efficient control systems and process engineering to LOI THERMPROCESS GMBH Moltkeplati 1 ensure economic production Essen Germany Phone +49(0)201/18911 Fax +49(0)201/ Internet http//www loi de

6 simple highest standard Super Alloys and Austenitic Steels SUPERBOLT The attractive way to bring together strength and intelligence Superalloy 706 forgings for land based 322 turbines Takashi Shibata, Terutaka Kure Large forgings of alloy... based gas turbines Samuel V. Robin C. Tatsuya Takahashi, Junichi Taira, Thamboo, Ling Yang, Schwant 706 and 718 for land 330 Manufacturing technology and material 336 properties of heavy austenitic stainless steel forgings Yoshihiko Funakoshi, Katsuhiko Tokuno, Tetsuya Shimada, Tohru Kuwaki Optimisation of the open die forging of 344 heavy pieces in stainless steel through the control of grain Jean Pisseloup, Pierre Bocquet, Isabelle Poitrault, Rene Dumont for large bolting free of torsion no special tools highest tension and fast, also when untightening without setting safety low cost program: M20M160 special designs available Products Forging of highly sophisticated products 349 KarlErich Piper, Volker Schuler Outfitting a 13,000 t extrusion press with 356 two 4part containers H. Wagner, K.H. Schonfeld, R. Meilgen, T. Dincher Manufacturing of heavy wall hydrocracking 363 reactor made from advanced CrMo steel Tatsuo Hasegawa, Rinzo Kayano, Hiroshi Iga, Tohru Ishiguro SUPERBOLT tensioning "['[, systems: trojig + simple Forging and cold stretching of aluminium for space applications Knut Escher, Wojciech Harabasz, Paolo Gallo, Edoardo Tacchino Metallurgical properties steel for back up rolls of 5% CrMoV 377 and effect of hardness on major properties affecting the inservice behaviour Giovanni Perni, Angelo Finali, Aldo Berretta, Lino Callegari P&S Tensioning Systems Ltd. CH8735 St.Gallenkappel Switzerland Tel +41(0) Fax+41(0) ch Development of deep hardened work roll 383 for cold strip mills YoungChul Park, GueSerb Cho, JongWook Lee, JeiYeong Jeon, llbong Kim, HyunMun Kim Development and application results of the 389 low hardness piercing roll Shouitsu Seo, Satoshi Matsuoka, Taro Kanayama, Akira Yorifuji

7 STRAHLEM ERSTER KLASSE: RAUPENBAND STRAHLANLAGEN Tester) Sie unser erfolgreichstes Strahlmasdiinenprogrammzum Reimgungsstrahlen und Verfestigen schwerer, stark ausgeformter kantiger Werkstiicke und grorer Chargen. Raupenbandkonstruktionen mit schweien Stahllaschen und hoher VerschleiBfestigkeit 5chleuderrader der neuesten Generation verkurzen Strahlzyklen und vermindern den Fnergiebedarf Klare Bedienelemente sowie vorprogrammierbare StrahUyklen Mmimaler VersdileiB 24StundenGarantie fur Service und OnginalErsatzteile AuBerordentlich hohe Wirtschaftlichkeil duidi niednge Betnebskosten und hervorragendes Preis/Leistungsverhaltnis bei hohem Quahtatsniveau Planung, Projektierung und Fertigung aus einer Hand Fordern Sie Informationen an. MM^^WHEELABRATOR V^=~BERGER WheelabratorBerger Maschinenfabriken GmbH PollVmgster StraRe Koln Tel Tax de Internet wwwwheolabiatorbergerde usf 58 ovoo Design and Manufacturing of a High 397 Nitrogen 12% Chromium Steel for Gas Turbine Disk Applications Alkan Gocmen, Jorg Pross, Peter Ernst, Gerald Stein Testing and Quality Management Quality key data and process key data as 402 basis for reliable supply of large forgings Michael Brandle, Ernst Potthast, Werner Wiemann Quality assurance for high integrity forgings 407 David Street, Alan Oldale Integrated statistical process control (SPC) 414 at Saarschrniede GmbH Freiformschmiede N. Blaes, J. Meiser, H. Wagner Recognition and calculation of the plastic 421 constituent of deformation during impact testing of samples subjected to brittle fracture Valery A. Tiurin, Vladimir V. Ovechkin VAUTID HHrtautlrag'iChwoisson leicht gomaclitl VAIMIU VIRC< Hl.1 VAUTID: Hartauftragschweissen leicht gemacht! Emfache Regeln zur Auswahl des Auftragschweisswerkstoffes und des Auftragschweissverfahrens zum Panzern unterschiedlicher Grundkorper Bitte fordern Sie unseren Prospekt an VAUTIDVERSCHLEISSTECHNIK Drlng Hans Wahl GmbH OstfildemRuit bei Stuttgart Postfach41 10 Telefon 07 11/ Telefax 07 11/ de Internet http//www vautid de Ultrasonic Inspection Innovative mechanised inspection technique... replaces manual inspection of heavy forged rotors Angelo Final!, Renato Borgna, Klaus Leupoldt 426 Automated ultrasonic surface and volume 429 testing of contoured discs Knut Escher, Gerald Stein, Sebastian Gripp First experiences in testing heavy forgings with an advanced automatic ultrasonic testing facility Helmut Pfeiler, Gunter Zeiler, Robert Bauer 435

8 schnell, Wir bieten die Technik Unser Verfahren zum Entzundern von Schmiedestucken vereinigt viele Vorteile: Qualitatsverbesserung durch allseitig entzunderte Schmiedestucke Steigerung der Wirtschaftlichkeit Ihres Produktes und Ihrer Anlage Integrierbar in Ihre Schmiedelinie Geringe Durchlaufzeit, max. 15 s fur den kompletten Vorgang GroSe Materialvielfalt in einer Anlage Rund mm Vierkant 80 Lange 100 mm mm Hydraulische Entzunderungsanlagen von SGGT vielfaltig, zuverlassig Saarlandische Gesellschaft for Grubenausbau und Technik mbh & Co. KG BahnhofstraBe 35 Tel.:+49/6824/3080 wwwsggt.de Ottweiler Fax:+49/6824/ Ultrasonic inspection of forged rotor shafts 439 by manual and automated systems comparison of results against true flaw size Dietmar Thumser, HansGunter Ambrosius, Gerhardt Hess, Manfred WeiB Simulation and Modelling Behaviour of graded materials during 440 deformation Swen RaBbach, Wolfgang Lehnert, Gunter Lehmann, Rudolf Kawalla Simulation of forging in flat and Vshaped 449 dies Valery A. Tiurin, Vladimir V. Ovechkin Simulation of ring rolling 454 Michael Hellmann, Thomas Hulshorst, Reiner Kopp Threedimensional finiteelement simulation 475 of stretching technological parameters W/H and of heavy forgings Liu Zhubai, Wang Leigang, Deng Dongmei Computer Simulation of technological chain 479 by free forging Bohuslav Masek, Zbysek Novy, Dusan Kesner, LotharW. Meyer Hot flow curves of metallic materials 484 J. Gottschling, P. J. Mauk PreComputation of material charcteristics of large forgings made from tempering steels Walter Grimm, Peter Sommer Process modelling and finite element 497 simulation of titanium alloy disc forging N. Srinivasan, N. Ramakrishnan, G. G. Saha New solutions for rolling rings in consistently highest quality Martin Gellhaus Technological expert system for ring and 468 flange production Ulrich Koppers Poster P1 Standardization of the Leeb Hardness Testing Method Dr. Jorg Sommer, Dr. Edward G.Nisbett Stefan Frank, 503

9 96 Coaching new PEDDINGHAUS GROUP ISCHMIEDESTUCKEAUS 1SACHSEN Uber 200 Jahre Erfahrung im Schmieden PreB und Schmiedewerk GmbH Berthelsdorfer Str BrandErbisdorf Telefon: Fax: Internet: Nahtlos gewalzte Ringe PSW typische Frelformsohmiedeteile Schmiedestucke aus Sachsen Wirfertigen ein breites Sortiment von Gesenk, Freiformund Feinschmiedestucken sowie nahtlos gewalzte Ringe fur alle Industriezweige. Beim Gesenkschmieden produzieren wir komplizierte Teile fdr die Fahrzeugindustrie, fur Baumaschinen und Gleisbau und weitere Branchen. Zum Freiform und Feinschmiedesortiment gehoren u.a. Waggon und Triebfahrzeugachsen, abgesetzte Rader und Wellen, Formteiie bis 3000 kg, nahtlos gewalzte Ringe bis 1000 mm A0 und max. 220 mm Hohe, Buchsen und Hohlwellen bis 600 mm A0 u. 800 kg, Scheiben, Lochscheiben bis 900 mm A0 u. 800 kg, Rund u. Flachstahl bis 6000 mm Lange in alien Werkstoffqualitaten, Warmbehandlungsverfahren und Abnahmen, roh und mechanisch bearbeitet. Nutzen Sie unser umfassendes Knowhow und sprechen Sie mit uns StahlRegression Dr. Sommer WERKSTOFFTECHNIK Anwendungslnstltut zur Elnsatzoptlmierung von Werkstoffen, verfahren. Wdrmebehandlung Applications institutefor theoptimisation of Material, Process and Heat Treatment Applications Computer modelling of heat treatm process and mechanical properties Dr. Sommer Werkstofftechnlk GmbH Hellenthalstrasse 2 D47661 issum Telefon: ' Telefax Hardenability P2 Wear reduction of forging dies by 505 application of ceramic multilayers Eckart Doege, Aziz Huskic, Dipl.Phys. Martin Eckel P3 Human resources management as part 507 of a TQM approach management Bettina Schneider, Christian Forster, Olaf Schroder, Prof. Dr. Klaus Kost P4 Through diamond technique of middle 509 possibilities for mobile hardness testing Dr. Stefan Frank P5 Integrated software solutions for 511 production and quality management of steel, roller and hammer works Andreas Kirsch, Michaela Schmid P6 PCbased data acquisition in a forging 513 plant as a means of production sequence optimization system Dr. Fister Gunter Schell PI Influence of melting technology on 514 properties of highchromium steel forging E. Y Kolpishon, A. M. Korchagin Advertisers' index 517

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