IFM 15th International Forgemasters Meeting
UNIVERSITATSBIBUOTHEn HANNOVER TECHNISCHE !Nf=ORMATIONSBIBUOTHB< j *"' -' -- * n I, ..,,., Proceedings
October 26-29, 2003 International Conference Center Kobe, Kobe City, Japan
UB/TIB Hannover 89 121 325 873 JSCFA Steel Castings and Forgings Association ofJapan Contents of Proceedings
WELCOME i
Hisashi Tsukada - Chairman ofSteel Castings and Forgings Association ofJapan
PLENARY: RECENT DEVELOPMENTS IN THE FORGING INDUSTRY
"The open die forging industry in Austria, Germany, Italy, Sweden, Switzerland and Czech Republic - in association with the steel institute VDEh" 1
R. Kopp & O. Ziegelmayer - Institute ofMetal Forming, Germany A. Frank - Steel Institute VDEh, Germany
R. Schmidt - Kind & Co Edelstahlwerk, Germany W. Grimm - Buderus Edelstahl, Germany
Technical development and questions of forging industries In Korea" 16
J. T. Kim - Doosan Heavy Industries & Construction Co., Ltd., Korea
"The current position of the UK forging Industry"
G. A. Honeyman - Sheffield Forgemasters Engineering Ltd., UK
"Recent developments in the North American open die forging industry" 22
K. J. Handerhan - Ellwood Group, Inc., USA
"Evolution in French forging industry during last years" 29
R. Dumont - Creusot Forge, France
"The Italian forgers Industry" 31
G. Astorri & S. Nogara - Federacciai, Italy
"Recent trends and technical developments in the heavy open-die forging industry in Japan" 33
T. Ishiguro - The Japan Steel Works, Ltd., Japan
SESSION 1: REFINING AND INGOT MAKING
"Large forging ingots, a processing overview" 39
J. E. Steiner - Engineering Materials & Processes Inc., USA
"Production of ultra low C steel by using 100-ton LF-V" 43
K. Iwanaga, M. Nishihara, K. Nishiguchi, M. Nagao & H. Ishida - KOBE STEEL, LTD., Japan
"Effective forging ingot making process using one large 120t EF —One EAF producing various 6-600tons ingots—" 51
T. Suzuki, H. Tamura, T. Ogawa & M. Funa/aki - The Japan Steel Works, Ltd.. Japan
"Application of hydrogen direct measurement equipment in molten steel to prevent hydrogen induced hair cracks in large ingots for forging" 59
M. Nagao, K. Iwanaga, K. Nishiguchi & M. Nishihara - KOBE STEEL. LTD., Japan
"Activity measurement of FeO in FeO - AI2O3 - Si02 slags" 65
P. K. Shrivastava - Mahatma Gandhi Chitrakoot University, India B. Indyk - University of'Strathclyde, UK
IV "Thermodynamic equilibria of CaO-CaF2-Si02-AI203(-IVIgO) slags and liquid iron" 70 K. R. D. S. J. T. Lee, J. I. - Kim, Kim, Hur, S. H. Ko, J. C. Choi & J. M. Kim Doosan Heavy Industries & Construction Co., Ltd., Korea
"The prospects for of large forgings segregation-sensitive alloys" 77 A. Mitchell - University ofBritish Columbia, Canada
"Prediction of freckle defects in INCONEL 718 VAR ingots" 84 K. Morita & T. Suzuki - Daido Steel Co., Ltd., Japan W. Yang & D. G. Evans - Special Metals Corporation, USA
"Advanced ESR concepts for high quality forgings" 89 H. Holzgruber & W. Holzgruber - INTECO special melting technologies, Austria
"36NI-Fe with ingot high cleanliness with ESR process" 94
S. M. - Ueda, Funazaki, K. Kajikawa, S. Tanaka & T. Shibata The Japan Steel Works, Ltd., Japan
"Experience with the new 8/16-t vacuum induction furnace at Saarschmiede" 102 K. H. Schonfeld & N. Blaes - Saarschmiede GmbH Freiformschmiede, Germany
- SESSION 2: METAL FORMING (I) FACILITIES AND EQUIPMENTS -
"The new state of the art 75/85 MN Saarschmiede GmbH forging equipment" 108 D. Bokelmann - Saarschmiede GmbH Freiformschmiede, Germany M. Baues - SaarstahlAG, Germany R. Dango & H. J. Grisse - DDSDango & Dienenthal Maschinenbau GmbH, Germany J. PoppenMger - Saarschmiede GmbHFreiformschmiede, Germany W. Schmitz - SMS Meer GmbH, Germany
"Experiences with the new GFM radial forging machine" 115
R. Wieser - GFM GmbH, Austria
"Innovations and new developments In open-die forging press and heavy rail-bound manipulator design" 123
A. S. Tuncel - SMS Meer GmbH, Germany
"The new forging machine RF 70 of Edelstahl Wltten-Krefeld GmbH" 131
C. Heischeid & K. E. Piper - Edelstahl Witten-Krefeld GmbH, Germany
"Laser measurements on large open die forging (LaCam-Forge)" 137 S. Kirchhoff & R. Lamm - Ferrotron Technologies GmbH, Germany
N. Milller & R. Rech - Edelstahlwerke Buderus AG, Germany
"Manufacturing technology improvements using new 3000-ton press" 141
K. Yamamoto & K. Tamura - Sumitomo Metal Industries, Ltd., Japan
"A new press with hydraulic sinusoidal drive enables forging with controlled variable strain rates" 149
B. MaSek - University of West Bohemia in Pilsen, Czech Republic and Chemnitz University of Technology, Germany
M. Pahnke - WEPUKO Hydraulic Melzingen, Germany
V. BernaSek - University of West Bohemia in Pilsen, Czech Republic
B. Sniegonova - 2t>AS a.s. Zd'dr nadSdzavou, Czech Republic
"New technological possibilities after modernisation of a 52 MN open die forging press" 152
F. Stampler, V. Wieser, R. Bauer, J. Biela & G. Lichtenegger - Bohler Edelstahl GmbH & Co KG, Austria
v "Improved heating process and reduced energy consumption in a forging furnace" 157
R. Schmidt & G. Winning - Kind & Co. Edelstahlwerk GmbH, Germany
O. Hatzfeld & W. Bender - Betriebsforschungsinstitut, Germany
H. Rinnhofer & E. Tschapowetz - Maerz-Gautschi GmbH, Germany
"Advanced regenerative burners for large forging furnaces" 165 K. Tsuruhisa, H. Koga, H. Nagasako & T. Kuwaki -Japan Casting and Forging Corporation, Japan
"Better pollution control and reduced energy consumption through improvements on the hydraulic drive system of a 55 MN open die forging press" 173
M. Pahnke - Wepuko Hydraulik, Germany R. Rech - Buderus Edelstahl, Germany
"Production and metallurgy results obtained by the new automatic forging system with oleodynamic press 25 MN" 177
R. Brandazzi & A, Franchini - Franchini Acciai S.p.A., Italy
E. Ceretti - Universita'di Brescia, Italy M. Baldassi - Danieli Breda, Italy
- SESSION 3: POWER GENERATION (I) HYDROELECTRIC, GEOTHERMAL -
"Latest developments for very big hydraulic rotor shafts at Sidenor Relnosa works" 183
J. Tezanos & M. Llanos - Sidenor R&D, Spain
"Development of a 12%Cr-5NI steel for geothermal turbine rotor (I) - Fundamental studies and verification tests-" 187 M. Kamada, M. Saito, A. Fujita & K. Ura - Mitsubishi Heavy Industries, Ltd., Japan Y. Okamura - Japan Casting & Forging Corporation, Japan
"Development of 12%Cr-5%Ni steel for geothermal turbine rotor (II) - Rotor forging manufacturing technology-" 192
T. Shirnada, Y. Okamura, K. Nakata & Y. Kuroda - Japan Casting & Forging Corporation, Japan M. Kamada, M. Saito, A. Fujita & K. Ura - Mitsubishi Heavy Industries, Ltd., Japan
- SESSION 4: POWER GENERATION (II) LOW PRESSURE TURBINE -
"Improvement of productivity for rotor forgings in JSW Muroran" 199
K. Kimura, H. Kudo, T. Nakamura & Y. Tanaka - The Japan Steel Works, Ltd., Japan
"Production of large diameter differential heat treated NICrMoV rotor forging" 205
F. Gatazka - GE Power Systems, USA Y. Wakeshima & T. Miyata - Japan Casting and Forging Corporation, Japan
"Qualification of generator field forging horizontal quality heat treatment" 212 F. Gatazka - GE Power Systems, USA K. Kimura & Y. Kishi - The Japan Steel Works, Ltd., Japan
SESSION 5: POWER GENERATION (III) - HIGH TEMPERATURE STEAM
TURBINE -
"High-temperature steel forgings for power generation machinery" 219
N. - Blaes, K. II. Schonfeld & D. Bokelmann Saarschmiede GmbH Freiformschmiede. Germany
"Manufacturing technology of high Cr high N steel ingot by vacuum stream degassing method" 227
II. H. Y. Nakano & H. - Nanise, Yaniada, Kawakami Japan Casting <& Forging ('orporation. Japan
vi "Development of welded rotors for high-temperature steam turbines" 232 R. Magoshi, T. T. Nakano, Konishi, S. T. & Y. - Nishimoto, Shige Kadoya Mitsubishi Heavy Industries, Ltd., Japan M. Mikami & Y. - Wakeshima Japan Casting & Forging Corporation, Japan
"Power plant - A to the forgings challenge manufacturers" 238 T. U. Kern, M. Braendle & A. Wiegand - Siemens Power Generation, Germany
"The European material development within C0ST522 for 650°C USC power plants" 244 T. U. Kern - Siemens Power Generation, Germany M. Staubli - Alstom, Switzerland
G. Zeiler - Boehler, Austria
A. Finali - Societa delle Fucine, Italy B. Donth - Saarschmiede, Germany
"9-12% Chromium steel for - forgings power generation plants experiences in manufacturing and long-term mechanical & microstructural testing" 248 G. Zeiler & W. Meyer - Bohler Edelstahl GmbH & Co KG, Austria K. Spiradek & C. Stocker - ARC SeibersdorfResearch GmbH, Austria
and "Development manufacturing of Co-contained 12Cr steel with high thermal resistance for steam turbine bolt and blade" 256
T. Furuse, H. Sakuma, T. Inukai & Y. Tsuruta - Daido Steel Co., Ltd., Japan
Y. Y. - Hirakawa, Kadoya, R. Magoshi & H. Kawai Mitsubishi Heavy Industries, Ltd., Japan
"Development of high WCoB-containing 12Cr rotor steels for use at 650°C in USC power plants" 261 M. Arai & H. Doi - Hitachi, Ltd., Japan T. Azuma - The Japan Steel Works, Ltd., Japan T. Fujita - The University of Tokyo, Japan
"Improvement of long term creep strength in high Cr heat resistant steel" 269 K. Miki, T. Azuma & T, Ishiguro - The Japan Steel Works, Ltd., Japan R. Hashizume - The KansaiElectric Power Company, Inc., Japan Y. Murata & M. Morinaga - Nagoya University, Japan
"Manufacturing technology of 12%Cr steel alloyed with boron large ingot for power generator" 276 S. Nozu, K. Morinaka, H. Naruse & T. Muraoka - Japan Casting & Forging Corporation, Japan
"Production and characteristics of modified 9CMMo steel forging for valve bodies" 282
Y. Yamamoto, Y. Akimoto, Y. Hayashi & S. Seo - Pacific Steel Mfg. Co., Ltd., Japan
"Development of the advanced 12% Cr steel valve forging for the power plant" 290
E. Amada & S. Seo - Pacific Steel Mfg. Co., Ltd., Japan Y. Kadoya & R. Magoshi - Mitsubishi Heavy Industries, Ltd., Japan
"Forged and cast steam chests in a new ll%Cr steel" 297
P. Bates & I. Nicholls - Sheffield Forgemasters Engineering Ltd., UK
D. V. Thornton & R. Vanstone - Alstom Power Ltd., UK
SESSION 6: METAL FORMING (II) - FORGING TECHNOLOGIES -
"Quality improvements and new material developments by using hydraulic radial forging machine" 303
P. Nieschwitz - SMS Meer GmbH, Germany
"Controlling grain size in the manufacture of large open-die forgings" 310
W. Grimm & F. Hippenstiel - Edelstahlwerke Buderus AG, Germany
"The influence of manipulation forces on the quality of open-die forgings" 318
R. Dango, H. J. Grisse & S. Krusch - Dango & Dienenthal Maschinenbau GmbH, Germany
vii 326 "Near netshape production of seamless rolled rings with an outer profile by controlled displacement"
H. Meier & A. Pentleit - Ruhr-University ofBochum, Germany
"Influence of various heating and forging routes on the microstructure of 3%Ni-steels" 331
J. Sarnet - Scana Steel Bjorneborg AB, Sweden
B. Widell - KTH Royal Institute of Technology, Sweden
"Forging of ingots and bars with flat dies using macroshear deformation" 336
V. A. Tyurin & V. V. Ovechkin - Moscow State Institute ofSteel and Alloys, Russia R. Kopp & O. Ziegelmayer - Institute ofMetal Forming, RWTH Aachen University, Germany
"Success in ring rolling" 340
U. Koppers - SMS Eumuco GmbH, Germany
"Forging Ingots of new shape and methods of their processing" 353
V. A, Tyurin & V. V. Ovechkin - Moscow State Institute ofSteel and Alloys, Russia
SESSION 7: METAL FORMING (III) - MODELING -
"The production of gas turbine disks" 356
J. Husmann - SMS Eumuco GmbH, Germany
"Numerical and experimental simulation of the design of sized compressor disk for the ACDR-procedure" 367
M. Franzke - Institute of metalforming, Germany
W. Harabasz - Schmiedewerke Grdditz GmbH, Germany
A. Lieb & J. Flusmann - SMS Eumuco GmbH, Germany
"Uniform deformation In open die forging by optimized pass schedules and bite-shift" 375
H. Lundback - MEFOS, Sweden
J. Sarnet - Scana Steel Bjorneborg AB, Sweden G. Hagelberg - Uddeholm Tooling AB, Sweden
T. Mauritzon - AB Sandvik Materials Technology, Sweden
J. Sondell - Erasteel KlosterAB, Sweden
E. Odegard - Scana Steel Stavanger as, Norway
"Study on the critical values of anvil width ratio and blank width ratio and the processing parameter matching of NFM forging method" 383
C. Liang & Z. Liu - Yanshan University, China
S. Wu - China First Heavy Machinery Group, China L. "Ni & L. Wang - Yanshan University, China
"FEM modelling of thermal and deformation behaviour in open die forging" 387 S. Shamasundar, S. Habbu, B. Sonhar & V. Janardhana- ProSIM, India
"Identification of instabilities in radial-axial ring-rolling processes using multivariate detection methods" 394
H. Meier & P. Lagao - Ruhr-University ofBochum, Germany
"ForgeBase - A tool for optimization of the open-die forging process" 398
W. Schmitz - SMS Meer GmbH, Germany
"Computer simulation based optimisation of open die forging operations to achieve desired microstructure" 403
S. Shamasundar, S. Habbu, B. Sonhar & V. Janardhana - ProSIM. India of LZ "Application forging method and NFM forging method" 408 Z. Liu - Yanshan University, China S. Wu - China First Heavy Machinery Group, China L. Ni - Yanshan University, China H. Sun - China Second Heavy Machinery Group, China G. Liu - Yanshan University, China
Y. Liu - Beiman Special Steel Co., Ltd., China
P. Zhang & Z. Li - Taiyuan Heavy Machinery (Group) Co., Ltd., China
"Simulation of a new upsetting theory for H/D>1 cylinders" 411 Z. Liu & L, Ni - Yanshan University, China S. Wu - China First Heavy Machinery Group, China C. Liang & G. Liu - Yanshan University, China D. Deng - Guodian Nanjing Automation Co., Ltd., China
SESSION 8: CRANK SHAFT AND OFFSHORE
"Implementation of the improved TR-method of forging crankshafts" 416 T. Rut & W. Walczyk - Metal Forming Institute, Poland
W. Harabasz - Schmiedewerke GmbH, Germany
"Finite element simulation of RR forging for solid type crankshafts" 423
H. Kakimoto, T. Chouda, H. Takahara, Y. Takahashi & H. Mori - KOBE STEEL, LTD., Japan
"A707 2M-The next step In offshore materials" 429
R. M. Goddard, P. Bates & M. W. Crabbe - Sheffield Forgemasters Engineering Ltd., UK
SESSION 9: POWER GENERATION (IV) - NUCLEAR PRESSURE VESSELS AND
CASKS -
"Neutron irradiation characteristics of the reactor vessel materials for APR 1400 in Korea" 434
J. T. Kim, H. K. Kwon, B. I. Yang & K. C. Kim - Doosan Heavy Industries & Construction Co., Ltd, Korea
B. S. Lee & J. H. Hong - Korea Atomic Energy Research Institute, Korea
"Manufacturing and properties of closure head forging integrated with flange for PWR reactor pressure vessel" 440
T. Sasaki, Y. Koyama, I. Kurihara, Y. Tanaka & K. Suzuki - The Japan Steel Works, Ltd., Japan
"Manufacturing of large size forged transition cone by advanced forging process" 448
Y. Kumagai, H. Kudoh, K, Saitoh & N. Ozaki - The Japan Steel Works, Ltd., Japan
"Development of manufacturing technology on body-base monolithic cask forging" 456
S. Kuri & K. Ishii - Mitsubishi Heavy Industries, Ltd., Japan
Y. Funakoshi, K. Tokuno, N. Mizuno, T. Tsunezumi & T. Tomomatsu - Japan Casting and Forging Corporation, Japan
SESSION 10: SUPER ALLOY, AUSTENITIC STEEL, Ti ALLOY
"High-alloy steel and nickel-base alloy products made from electroslag-remelted Ingots up to 165t weight" 464
N. Blaes & K. H. SchOnfeld - Saarschmiede GmbH Freiformschmiede, Germany
IX "Mechanical and microstructural qualification of a prototype IN718 forged disk" 471
A. Finali & M. Calderini - Societa delle Fucine, Italy A. Di Gianfiancesco, 0. Tassa & L. Cipolla - Centro Sviluppo Materiali, Italy
R. Montani - Acciaierie Foroni, Italy "Large forgings of modified alloy 706 for land based gas turbines" 479
T. Takahashi, T. Shibata, J. Taira & T. Kure - The Japan Steel Works, Ltd., Japan
"Development and manufacturing of Ni-based superalloys with low thermal expansion for steam turbines" 487
T. Furuse, H. Sakuma, S. Ueta, T. Noda & S. Isobe - Daido Steel Co., Ltd., Japan R. Yamamoto, Y. Kadoya, H. Kawai & R. Magoshi - Mitsubishi Heavy Industries, Ltd., Japan
"Alloy 718 for large forgings" 492
H. Kuchler, V. Wieser, R. Bauer & F. Stampler - Bohler Edelstahl GmbH & Co KG, Austria R. Bode - Siemens Power Generation Industrial Application, Germany
"Nitrogen alloyed high strength austenitlc materials for power station components" 500
G. Stein - Energietechnik Essen GmbH, Germany
I. Hucklenbroich - Krupp Edelstahlprofile GmbH, Germany
"The biggest retaining ring ever made out of a high nitrogen steel for 300 MW asynchron-motors/generators in a pump-storage-power plant" 506
G. Stein - Energietechnik Essen GmbH, Germany M. Sertorio - Forgiatura A. ViennaS.P.A., Italy
R. Kirchengast - VA Tech Hydro GmbH & Co., Austria
"Creep behaviour of isothermally forged titanium alloy aeroengine compressor disc" 513
T. Raghu & G. G. Sana - Defence Metallurgical Research Laboratory, India
SESSION 11: ROLL AND TOOL STEELS
"Spray forming-The technology for high-grade tool steels of the 21st century" 518 I. Schruff & V. Schiller - Edelstahl Witten-Krefeld GmbH, Germany C. Spiegelhauer- Dan Spray A/S, Denmark
"Experience with polymer-quenching of large open die forgings" 526
K. Hiltner & R. Rech - Edelstahlwerke Buderus AG, Germany
"Improvement of the low hardness and high carbon piercer roll" 529
S. Matsuoka, M. Yagou & S. Seo - Pacific Steel Mfg. Co., Ltd., Japan
"Effect of the Wldmanstatten structure of a high carbon type large forged rolling roll" 537 M. Yagou, Y. Akimoto & S. Seo - Pacific Steel Mfg. Co., Ltd., Japan
"Advanced forged roughing mill work rolls" 545
M. W. Crabbe & M. G. Kearney - Sheffield Forgemasters Engineering Ltd., UK
J. Mees - ShefjieldForgemasters Rolls Ltd., UK
"Improvement of susceptibility to spalling of CGL roll steel" 550
T. Tsubota, T. Nakayama & N. Fujitsuna - KOBE STEEL, LTD., Japan
"Manufacturing process on highly hardened back-up rolls for plate rolling mill" 554
N. Fujitsuna, H. Nakashima & S. Hino - KOBE STEEL, LTD., Japan SESSION 12: NDE
"The relationship between UT size and reported actual size of the defects in rotor forgings" 561
U. H. & J. T. - Seong Kim Doosan Heavy Industries & Construction Co., Ltd., Korea
"Ultrasonic of inspection heavy forgings for power generation machinery using advanced systems" 564
D. - Thumser & J. Meiser Saarschmiede GmbH Freiformschmiede, Germany with the "Experience ultrasonic inspection of heavy forgings by different automated UT systems" 570 D. Thumser - Saarschmiede GmbH Freiformschmiede, Germany U. Bartzsch - Edelstahlwerke Buderus, Germany U. Btichner - Siemens Power Generation, Germany V. Knobloch - Schmiedewerke Groditz GmbH, Germany M. Weniger - Siemens Power Generation, Germany
"Automated systems for the inspection of big forged rotors for steam turbines" 575 K. Leupoldt & W. Meister - CEGELEC Anlagen- undAutomatisierungstechnik, Germany
"Mechanised inspection of hollow shafts of train wheel sets" 579 H. Hintze - Die Bahn AG, Germany
D. Heinrich, E. Hofmann & K. Leupoldt - Cegelec AT GmbH & Co. KG, Germany
"Automated US-immersion tank testing for rings and discs" 582
G. Stein & A. Koppelberg - Energietechnik Essen GmbH, Germany
"Development of expert system adviser for primary inspection and interpretation of defects by non destructive testing" 586
P. K. Shrivastava - Mahatma Gandhi Chitrakoot Gramodaya University, India R. Sharan - Centre of Plant Engineering Services, India
"Disaster management plan in Indian industries - legal implications and implementation" 593 R. Sharan - Centre ofPlant Engineering, India
B. A. Khan - Chotanagpur Law College, India
XI