Steel Forgings: Design, Production, Selection, Testing and Application, Manual 53 0803133693, 9780803133693, 9780803145603

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Steel Forgings: Design, Production, Selection, Testing, and Application Edward G. Nisbett

ASTM Slock No. MNL53

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ASTM IDlematiooal . . . . . .TJOf&U

100 Barr Harbor Drive PO Box C700 West Conshohocken, PA 19428-2959 USA

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Printed in U.S.A.

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Ubrary of Congress

library of Congress CataJoging-in-Publication Data. Nisbett, Edward G. Steel forgings: design, production, selection, testing, andapplica1ion / Edward G. Nisbett.

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"ASTM Stock No. MNl53." ISBN 0-8031-3369·3 1. Steel forgings. I. Tille. TS320.NS92005

672·-dc22 2005020481

Copyright C 2005 ASTM International, West Conshohocken, PA. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film , or other distribution and storage media, wi thout the written consent of the publis her. Pbotocopy .RiPts Authorization to pbotocopy ｩｴ･ｾ＠ for internal, personal, or educa· tional danroom use, or tbe internal, personal, or educational cluaroom use of $pedfic cHeats, is granted by ASTM International provided that the appropriate fee is paid to the Copyright Clearance Center, 222 ROAewood Drive, Danven, MA 01923j Tel: 978-750-8400j online: http://_. copyright.c:om/. The Society is not J"eSpOlU'ible, . . . body, for the statements and opinions expressed. in this pubHcation. Printed in Bridgepon, NJ September 2005

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Foreword nns

PUBUCAll0N, SIMI Fc.F>lp; Dtstrn. Production, SNcw.as spomored by ASTM Cornmil-

fia,., Testin& ,,00 AppIiauion,

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lee AOI on Steel, Stainless Steel.nd is Edw.rd G. Nisbetl.

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Alloys. The authot"

Contents Chapter 1: Introduction: Why Steel Forgings? . .... . . .. .• . .. ... . .. ...... . .............. ... .... .. 1 Chapter 2: Why Use Forgings? .... . . ........ ............ ... ...... ........ .. ............. ......... 5 Steel Plate . . Hot Rolled Bar. Steel Castings ................ . . Steel Forgings ................ . .

... . . . . .• . . . . . . . .. ... 5

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Chapter 3: Effect of Steel Making ............. •...... . .•..... . .. .•..... ..... •................... 15 ..• .. . . . .

Steel Refining . . . . . ladle Refining furnace. Vacuum Degassing Steel Cleanlinf'SS and Indusion Shape Control.

. .. . ... . . . . 15

. . . . •. . . . . . . • • . . . . . . .. . . . 16 .... • . . . . .. . . • . . . .. . . . . . . . 16 . . . . . . . . • . .. . . . . . . . . " .19

Chapter 4: Forging Ingots ...... .... ... ........... ...... . ... .. ..... ......... , ............. ,', ..... , 20 Vacuum Arc Remelting . . .. . . . . .......... . .. . . . . . . . . . . . Electroslag Remelting. Ingot Mold Design, Ingot Production and segregation . . . Forging Stock .... . . . . . • . .

.. . . . . . .20 . . . . . . . . . . . .21 . . . . • . . . .. . . . . . . . . 22 . . . . . • .. . . . . . . .... 22

Chapter 5: Types of Forging .. ............ , ..................... , . . ....... , .... .......... ,., ...... 24 . ...24 . ... 25 . . ..25 . ...26 . .. . . .27 . .. •. . .. 27

Open Die Forging . . ........ . .... . . • . . . Clmed Die Forging . . Extrusions Rotary Forging Machines Ring Rolling. . ......... . . . . •• . . Forging Reduction.

Chapter 6: Heating for Forging ...... . ... , ............. . . 1, ...... ........ , . ............ "., •.•..• 32 . . .. •. . . . . .. . •. . . .... . . . . . . 32 . .... . . •• . ... . .. . . . . . •33 . . . . . . . . . . .. 33

Heat to Forge Furnaces. Reheating .. . Induction Heating . ...... . . . . . . ' . . . . • ...

Chapter 7: Post Forge Practices ........................... , ...... ... ..... , . . .. .... .. .... , . .... . .. 34 Chapter 8: Machining .................. . .......... ........ .. ........ ...... , .. . 0 . . . . . . . . . 0' . ' . . . . . . 36 Grinding . ........ . . . ........... •• . . . .

. •• . . .. • . . • . .. . . . . .•. . .. . . . . . . .. . . 37

Chapter 9: Heat Treatment .......... ... .. ... , ... .. .................. Annealing . •. . . . . .... . . . . .. . Mitro-Alloyed Forgings. Carbon and Alloy Steel Forgings ... . Heat Treatment Equipment Furnaces .. . . Batch Furnaces. Horizontal Furnaces . . . Vertical Fum«es Cont inuous Furnaces ...... . . . . . Induction Heating ......... .. . .. . . Controlled Atmosphere/Vacuum Fumaces •. .. Cooling/Quench Facilities. Uquid QuerKhing . ..........•... Water QuerKhing • . Oil Quenching • ............ Polymer Quenching ....... . .• . Polymer Concentrations. Spray QUl!rKhing

0' •• • • • • • • 0, . . . . , . . . . . .

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...... . . • . .. . . . .... . . .41 . . . . . . . . .42 . . .42 . .. . . . . .42 . .. . . . . .43 . .. .43 . . . .43 .. . .43 . . .43 . . .43 . . .45 . .. 45 . . . .45

• . . . . . . . . •.. 46

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Alternate Heat Treatments . . . Heat Treatment Rigging . . . .... ... . Hot Rigging Cold Rigging . Tempering .

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Chapter 10: Mechanical Testing ......... ...... .. .... .. .. ..... ....... .. .... . ... ... ... . ... .. .... . ... 53 . . . . . 54 .55

Hardness Testing ... . Tension Testing .. . . . Impact Testing .. . fracture Toughness Testing .. fatigue Testing ... . . . . . .. .

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Chapter 11: Nondestructive Examination ... . ... .. ... .. .. .. .. ............ . ..... ... .. .... . .... . ... . 59 Surface Examination . . . . . •. 59 Visual Examination . . . ... . .59 Magnetic. Particle EKilmination . . . . 60 Uquld Penetrant hamination . . .61 Volumetric hamination . . ....... . . . .• 62 In-Service Inspection .• . . ..• ..... . . . •..... . . . • . .. . . . . . ••...... .• .•. . . . ..• . ..•. . . . ..•. 65

Chapter 12: Surface Treatment . .... .. .. .......... .. . ...... ...... . ............. ........... . ...... .. 66 Direct Hardening ... . Nitriding . . . ...... . Gas Nitriding Ion Nitriding . . . . .... . Carburizing .... Salt Bath Tre atments .. Cold Working .

. ...•. • ....•.•. •. .... . . . .. . .66

. . .•.•.••• . .•.....•• .67 . . • . . . . . . . .•...... . . . .. . .... . . . . . . 68 . .. . .. . ..... . .. . ............ . . . . .. . . . . . . .... . . .69 . ... 69 . .... .. . . ..... . . . . . .... ... ...... . . . . . . 70

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Chapter 13: Manufacturing Problems and Defects .. . .... . .. .... . ... .. ... .. .... . .. ...... .. ...... 72 Base Material Choice . . . Ingot Defects . . . Ingots Size and Choice 8i11et / BIoom Size and Source . . . Heating for forging .. . • . ...... . Induction Heating ..... • ....... . Forging Operations and sequence . Machining . Post Forge Handling/ Heat Treatment

.72 . .. . . . . . . .72 . .. . . . . . . .74 . . • .•.•.•. • ..•.•.•... . . 14 . .•.•. • . • . .• . • . ..•. 75 . .. 76 . .. . . • .•.. . ...•.• . •. 76 . . . .. 76 . .... 76

Chapter 14: A Word about ASTM International. Committee AD1 on Steel. Stainless Steel. and Related Alloys. and General Requirement Specifications for Forgings •.•..•.•.••.•..•.• 78 Writing Standards. . . . . . .• . . . . . . . .•.• . . . . 1B ASTM Internat ional Steel Forging Standards . • . . . . . . .. . . . . . . .... . . .. . .. 18 . . . .... 19 General Requirements Specificatiom . . .. .79 General Requirement ｓｰ･｣ｩｦｾｴｯｮ ｳ＠ for ASTM Steel Forging Specifications. . .. •. . • .•.•. . .79 A 788-04 Steel Forgings. Ge neral Requirements . . . . . . . . . . . . . . ..•.•... . SpecifICation A 961lA ＹＶＱｍｾ＠ Common Require me nts for Steel Flanges, Forged Fitting$, Vallll!S, and Pam for Piping Applications .... • .•....• . • . . . . . .. . . . . . . . .82

Chapter 15: Steel Forgings for the Fittings Industry .. ................. .............. . .. . .. .. .. . 84 . .84 A 10S/A 10SM-{)3. Carbon Steel forgings for Pip ing Applications. .. . . . . . ...... . . . . . ...... . .... A lBl / A 181 M-{)l. Carbon Ste el Forgings for General Purpose Piping . . . . ..•... . . . •.•. . . . ....•........•. 85 A lBUA 182M-{)4, FOI"ged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings. and Valves and Pam for High Temperature Servke . . . . . . . . . . . .... . . . ....•.•....•.•.•..86 A 350/A 3S0M--04a, Carbon and low-Alloy Steel Forgings, Requiring Notch Toughness Testing for Piping Components .. . . . . . . . . . . . . . . . . . . . . . . . . ...... . ..•.•..• . . . .... . . . . . •.• B6 A 522fA S22M-()4. Forged or Rolled 8 and Ｙｾ＠ Nkkel Alloy Steel Flanges. Fittings. Valves, and Pam for Low-Temperature Servke. . . . . . . • . . . . . .•. . . . ..•.•. . .88 A 694/ A 694M-OO, Carbon and Alloy Steel forgings for Pipe Flanges, Fittings. Valves, and Pam for High·Pressure Trammiuion Sl!rvke .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . .89 .89 A 107lA 707M-{)2. Forged Carbon and Alloy Steel Flanges for Low Temperature SeMee ..... . A 727 / A 727M-OO. Carbon Steel Forgings for Piping Components with Inherent Notch Toughness . . . . .. .. ... .•.. .. . .. ... .•.•.. . .89 A 836 / A 836M-{)2. SpecifICation for Titan ium-Stabilized Carbon Steel Forgings for Glass-Lined Piping and Pressure Vessel Service . . . . . . . . . . . . . . . . • . . . . . . . . . . •. . .. . . . . . •... . . 89

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Chapter 16: Forg ing Re lated Test Methods .. .. ... .. ....... .. ..... ... .... . .. ................ .. ... 91 Magnet ic P.., icle Eumination ...••................... ..... . .•. •.•.• ... . .. .................••... 91 A 2751A 275M-9&, Test Method for the Magnetic P..,ic le h.min.tion of Steel forgings ....••.••........91 A 966 / A 966 M-96. Magnetic Particle Eumination of Sleel Forgings USing Altern.ling Current ....•••......92 A 4S6 / A 4S6M-99, Magnetic. Particle Eumination of L..Irge Cr.,bhlft FOtgings ••......... . .....••••... 92 A 981i / A 986M. Magnetic Particle Eumination of COntinuQUJ Gr.in f low Cr.nkase forgings . .•... . ..•... 93 ｕｬｴｲｾｩ｣＠ Eumin.tion •.•...... • •••.•.•.••••.....•....•• . ......•.• • .•.••..•..... . .. . ..•.•... . . 93 A 388 / A 388M-04, Ultrasonic Examination of HNIf)' Steel forglng'! ...•.•..•.•........• . .... . . . ...••.. 93 A 745 f A 745M-94, Ultrasonic Eumin.tion of Austenitic Steel FOtgings •.•.••..•••.•....•......•..••.• .9S A 418-99, Ultrasonic Eumination of Turbine.1"Id Gener.tOt Steel Rotor Forgings .••. . ....... •• •.•.••.• .9S A S031A 503 M. Ultrasonic hamin.t"ion of FOtged Cr.nksh.4fts••... . •......••.•.•..•..... , ...•. . •••. •9S A 531 / A 531 M-91, Ultra§OOic hamination of Turbin.e-Gener.tor Steel Retlining Rings . .• . • . . • •. . ..•..••96 . . .. • . •••. 96 A 939·96. ｕｬｴｲ｡ｾｩ｣＠ Eumination from Bored Surf.ces of cyllndril;.1 forgings .•.•.... . ....•96 General Comments .... . . ... .. •96 Portable H.rdness Testing Standards .....• . ..•...•••.. . .... 96 A 833. Il"Identatlon Hardness of Metallic Materhlls by Compariwn H.rdness Tenen . • . •. . •.. . , .. . . .•.• 97 A 956·02. lHb Hardness Testing of Steel Products •.•.•....•.• . .•.. . . . . . .•.•.. Other Portable Hardness Testing Methods ....•...•.•..••..•.............•.•.......... • .. . .... 98 . .. 98 Heat Stability Testing . . .. . •...•.•....•.•.•..•••.•.•.•.••.. . .. . . . ..•.•.... . . .• 9B A 472-9B, Heat Stabi lity of Steam Turbine Sh.f1s.nd 1I0tor Forgings . . ... _ . ..•......• . . Macro Structure ｔｾ＠ ..••••.................•....•.•. • .•.. . . . . . .... . .•.•....•. A 604-93, ｍ ｾｯ･ｴ｣ｨ＠ Testing of Conwmable Elec1 rode lIemelted Steel ･Ｎｾ＠ and Billets . _ •.•.. •• ... . . .. 99

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Chapter 17: Steel Forgings for the Pressure Vessel Industry ... .. .. . ..... ... ... , .. .... , . . , ... 100 A A A A

266 I A 26Ei M-03, c.rbon Steel Forgings tOt Pressure Veswl Components • .••••...•..•...•. , • ••.....••. 100 336f A 336M-04, Alloy Steel Forgings for Pfes:sure and High Temperal ure Paru ........••.•.•...••••••• 101 372 / A 372M-03, Orbon and Alloy Steel For-gings tOt Thin Walled Pressure Vessels ......•••• , • ..••..... 102 Steel 508/ A 508M-04b, Quenched and Tempered V.wum Tre.'ed Orbon a-rId ａ ｉ ｾ＠ forgmgs tOt Pressure Vessels . .......•............• . • .. ..• . •......•....•.•.... . .....• . ...... . . 103 ChemiUlI Composition ot Actual Grade 2 Forgings ..... •. .•.•..••....•......•....•.....••.... . . . . 103

ForgIng Dime-nsions ....... , .•• , .•.••• ,., •..•..•....••..•• , •.•.•..•........... . .... , ... . •... 103 Heat Treatment •.........•.•••• ,., ••.•...•....•. ..• •...•.• ,., •.• , ..........•.. . • ..•.. . . . . . 104 Nil Ductility Test Temperature (Per ASTM Spe