METALLURGY DEPARTMENT

Overview of Metal Forming

Processes

Sand Direct/Primary
Forming Forging
Casting Processes
Rolling
Investment
Casting Extruding
Indirect/Second
ary Forming Drawing
Powder Processes
Metallurgy

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Forging Process Review

There are three
main forging
methods

1 2 3

Open die forging Closed die

forging Ring forging

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1. Open Die Forging

Forging is done at temperatures in excess of

1,000C. Note color of billet.

Forging presses can range from 1,000T to

50,000+ T

There is no restraint on the flow of the

material after pressed.

8,000T Press

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Transformation of the Cast Structure to a

Wrought Forged Structure
Forging will close off porosity and
stretch out any segregation.

Note the
presence of
porosity &
segregation
in the ingot.

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Forging Effect on grains

Heat
softens
Forging Reduction Ratio
Forging Press
the bar
Cross
and allows sectional area ingot
hammer to
deform
= normally ≥ 3:1 Notice the
bar. grain flow
Cross sectional area
after forging

Cast Ingot

Press reduces the

diameter of the bar in
excess of 3:1

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Examples of Oil & Gas Open Die Forgings

Spool body forging

BOP forging
Larger size
Spool body forging components
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 METALLURGY DEPARTMENT

Onlybar
Forged problem
used to is that
make it isCameron
many only
Products
pressed in the rolling direction
Forging is only in
the rolling Advantages
Guideline
direction recommendations
1. Forged or rolled bar is
1. Only use forgedavailable.
commercially bar when
the design allows for pre-
Charpy Impact
Properties 2. heat
Forged
treatismachining
cheaper than
and
affected, presence
a forging.of No
a good bore.
queue
particularly
large diameters time and not necessary
2. Some designs
to use may need
large presses.
to be produced from a
3. forging
Bar canto be
achieve the to
machined
desirable properties.
the pre-heat treat
dimensions & heat
treated.

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 METALLURGY DEPARTMENT

2. Closed Die Forging

Direction of
Movement

Hot Metal Billet being Material flows to fill mold

Billet squeezed shape

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Examples of Closed Die Forgings

Finished
choke
valve

Choke valve body

Gate valve body

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 METALLURGY DEPARTMENT

3. Ring Rolling Process

1 2 3

4 5

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 METALLURGY DEPARTMENT

Example of use in Connectors FORGING

2 types: CHC and CVC

connectors
MACHINING
• Connection systems are used to
enable pressure tight connections
between subsea production
systems.

• Items such as flow lines, SLITTING

umbilicals, manifolds & trees.

• fluid is allowed to travel thru the

connection.

• Uses a series of 4⁰ tapered COLLET SEGMENT

segments to provide primary

locking mechanism.

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Sample Locations
T

¼T

T
4” 8”

4”
8” 8”
10”
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 METALLURGY DEPARTMENT

Forgings: Mechanical Properties

T
Why do tensile & Test Requirements@1/4T
charpy in two
directions? • Transverse tensile

• Transverse Charpy

• Longitudinal tensile

• Longitudinal charpy

¼T

T
4” 8”

4”
8” 8”
10”
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 METALLURGY DEPARTMENT

Review of a Forging Certification

MS Material

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 METALLURGY DEPARTMENT

Example of Test Locations from Drawings

The gauge length of the

tensile bar must be
outside of the heat
treat buffer

Heat treat cover

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Example of 1st article data from a MAME Tree

Spool Forging
Start with the 3X sacrificial sections
prolongation

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MAME Tree Spool Forging- Prolongation

Mid-section1 2
Sacrificial
(KSI) (KSI) Sacrificial
Forging Prolongation
section 2 data NQT & SRSacrificial section 1
(21.87"
(11" wall
wallthickness)
thickness) (7.5" wall thickness)
Yield Yield

Yield (KSI)
95
95 100

9197 96
96 96
90
89 95
90
90 89
88 94
88 93
93
86
90
85
85
tt
fafcac
thtehel & &
85 && a a tetded l
io nosns uduidninepeopror
i
80
80 ct atat gigt it e er r
Minimum
fa 75Ksi requirement lolcoch hlolnon nsnisl il
t he l & e d No
t et
No t b
e o ot tete
t
s & d i na po r t a a t beresrese
on u e 80 h h
t t nsnvsv
c ati ngit ile r trtara
e lo h lo n s
e
Minimum 75Ksi requirement
t t t
75
75 No t bo rse
t ha n s v e
tra 75

70
70
70

65
65
65

60
60
B-1-1/4
B-1-1/4 ; ; ; ; ; 60 ;
B-1-1/4 ; ; ;

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Example Closed Die Forging

Sacrificial
Sacrificial
section 1
section 3

Sacrificial
section 2

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