Do you feel the need for durable pipe fittings for your industrial operations? Well, there is nothing better than forged piping works in terms of strong fittings. That is why there is always no ebb in its demand among forged fittings manufacturers in India. This blog will touch on the reasons why forging is topic of discussion among manufacturers and chosen over the other processes. It will also describe in detail what methods are used in order to make flawless forged parts.
To understand forged types of components in a piping network conceptually, let us first look into what pipe fitting is. It is a piping connection that joins tubes, pumps, or valves to each other with the aid of fitting components. It is to say that such type of connector houses pipes on both ends ensuring a union. Its prime function is to offer an uninterrupted flow of raw materials without any leakage.
Now that we know what a pipe coupling is, let us head straight into the concept of forging and why it is hot topic among industries.
Table of Contents
Forged fitting :
Forging is a manufacturing procedure where metals undergo forming and shaping to produce various components. Such a method requires the application of compressive forces to mold metal into different forms as per the customers’ needs.
While selecting a metal processing technique, clients can get confused since each process has its shortcomings as well as advantages. It is advised that buyers keep in mind various points such as budget, targeted implementation, transportation costs and handling along with several other points before weighing their options.
Significance of forged fittings among different industries
Forging has been used since the emergence of metalworks in various aspects and fields. It has become possible to reduce the production cost as automation took over and hence forged metals can be produced in volumes. This means it is economically sound than other metalworks.
Forging offers improved grain flow, consequent reduction in lacunae and greater mechanical strength in a budget. All the physical properties of worked metal get improved greatly. It becomes inevitable to install fittings that can keep up with demanding work along with turbulent usage. Forged fittings are ideal for operations that require heavy stress and strain to be put on them.
Further customizations in compositional integrity make the metal fabrication set-up unimpaired. Forged fittings exporters in India rely a great deal on this due to its chemical as well as heat-resistant nature. When forging is applied to pumps and valves, they become ideal for usage in offshore industries, chemical, petroleum, piping as well as waterworks.
Ergo, forging is more advanced than any other fabrication procedure like casting or welding. This catapults it right at the top of current affairs for several businesses.
Different forging practices
Listing out methods of forging metals into components with their applications:
- Cold forging
- Hot forging
- Warm forging
We will look at each of these in detail.
- Cold forging
Cold forging employs the principle of high pressure and room temperature. Below are some of the most popular methods of cold forging.
- Smith forging
Malleable metal is placed between two dies namely upper and lower. One of the dies is attached to hammer or flat metal surface with concave edges, commonly the lower one. The upper die is rammed such that it impacts the heated metal. The fluid metal spreads out from the sides except where the die is pressing. Since dies cannot contain an entire metal block or sheet, it has to be aligned manually to obtain the desired geometry. Since none of the dies confines metal, the method is also known as open-die forging.
This is utilized to produce uncomplicated shapes including bars, tubes, rods. That is why it is widely employed in piping as well. Such a procedure is advantageous as it improves metal structure and grain size.
This forging type uses multiple dyes. One of the dyes in closed method is cast to have a negative replica of a component to be produced. Metal piece undergoes hammering between dyes multiple times. The first go-through gives it a rough shape. The next set of dyes provides it with generous amounts of bends and folds to manipulate the metal piece to resemble the desired outcome. Lastly, it is placed between the finishing pairs.
It involves rolling of metal bars in between two rolls facing each other. These bars are passed through rolls unless the desired size of the resulting product is not achieved. The grooves in rolls are placed such that they forge metal into accurate shapes. One of the benefits is it reduces flash production to a great extent. It is ideally used for automobile parts as well as hand tools.
- Press forging
This process directs the rate of internal strain of the metal. It involves gradual, constant pressure on the metal bar or sheet which allows it to deform at an atomic level. Distortion reaches the deeper level of metal and this allows for better precision. It is performed either mechanically or by hydraulic press.
Few other methods such as extrusion and deep drawing are types of cold forging. These two are extensively used to make forged pipe fittings.
- Hot forging
Metal bars are pressed into the opening of a die or machine. Hot forged fittings come out from the other end. The temperature of the bar is raised very high in very little time. It employs the principle of normal pressure, high temperature. That is why it is called hot forging. Fittings to be used in automotive as well as the aerospace sector can be made from such forging. But due to its high maintenance machinery, it is not very much liked amongst forged steel fittings manufacturers.
Forged fitting manufacturers including Gautam industrial corporation supply forged works to a plethora of industries. To enlist, they deal with refineries, the petrochemical sector, fertilizer industry, oil and gas operations, steel plants, shipbuilding, nuclear plants and engineering works.
Advantages of forged metal fittings
Mass production due to advances in forging machinery decreases time consumption and raises efficiency at many levels.
Not just that, minor disruptions in the metal are taken care of since hot forging changes the crystallization framework and arrangement of atoms. In addition to that, heating removes inclusion points from metals and therefore, eliminates potential stress points. This further reinforces metallic mechanical properties.
Cold fabrication restructures metal grains. This turns it into more desirable particles and strengthens its flow property.
Beyond this, it works best to cut out precision fittings as the methodology is based on automation.
Metals utilized in forging
Forging can be adopted virtually for any metal. However, some of those are more compatible with other fabrication methods. Metals that forged fittings exporters in India such as Gautam industries deal with are alloy steel, carbon steel, tantalum, stainless steel, cupronickel, Monel, Inconel as well as nickel.
Choosing the right pipe fitting
First off, determination of the material is imperative on the basis of specific demand. This should be based on the substance it is intended to transport and frequency of atmospheric exposure. Most heavy industrial functionings are compatible with metals like SS, carbon steel and alloy steel.
Next up, one needs to determine the type of pipe fitting required. The three types of fittings based on connection are
- compression – it uses pressure on uniting parts to secure the assembly.
- End – this kind of fittings have recipient surfaces that will accommodate pipe
- Flange – these are rims or collars with right-angled surfaces which will get connected to pipes by clamps, welds or threads
After deciding on the fitting type, sizing comes next. Proper sizing ensures leakage-proof union. The size of fitting depends on the pipe or valve size. There are different sizing units specified and monitored by ASME, API and ANSI. Another factor to consider is pressure and temperature allowance of the material.
To sum up the points discussed above, picking your ideal fitting is crucial for business to run expeditiously. Pipe fitting manufacturers including Gautam industries possess a diverse inventory with an abundance of different sizes of fittings.