80963539 Steel Forgings Design Production Selection Testing and Application

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

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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 ite~ 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

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

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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 .

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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 Specif~tions for ASTM Steel Forging Specifications. . .. •. . • .•.•. . .79 A 788-04 Steel Forgings. Ge neral Requirements . . . . . . . . . . . . . . ..•.•... . SpecifICation A 961lA 961M~ 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 A 10S/A 10SM-{)3. Carbon Steel forgings for Pip ing Applications. .. . . . . . ...... . . . . . ...... . .... . .84 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 9~ 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 Ultr~ic 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. Ultra~ic 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~ ..••••.................•....•.•. • .•.. . . . . . .... . .•.•....•. A 604-93, M ~oetch Testing of Conwmable Elec1 rode lIemelted Steel e.~ 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 ......•••• , • ..••..... 102 508/ A 508M-04b, Quenched and Tempered V.wum Tre.'ed Orbon a-rId AI~ Steel 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