High-Performance Superalloy Forging

Seamless Rolled Rings & Closed-Die Forging for Mission-Critical Applications

Forging for Fatigue Life: When structural integrity is non-negotiable, ForceBeyond delivers. We specialize in the high-temperature forging of nickel-based superalloys (Inconel 718, 625, Waspaloy) to achieve superior grain flow and fatigue resistance. From seamless rolled rings for gas turbines to high-pressure valve bodies for nuclear reactors, our AS9100-certified forging processes exceed standard metallurgical requirements.

gas turbine disc nozzle ring

The Forging Advantage: Grain Flow Optimization

Unlike machining from bar stock (which cuts through the metal’s grain structure) or casting (which has a random grain structure), Forging aligns the internal grain flow to the shape of the part.

  • Superior Fatigue Strength: Critical for rotating aero-engine parts and turbine discs.
  • Impact Resistance: Essential for nuclear pressure boundaries and safety valves.
  • Elimination of Porosity: A fully dense, wrought structure with zero internal voids.

Our Superalloy Forging Capabilities

1. Seamless Rolled Ring Forging
We manufacture high-strength rings used in jet engines, land-based gas turbines, and reactor vessels.

  • Process: Punching a hole in a heated billet and rolling it into a thin-walled ring.
  • Applications: Turbine Casings, Seals, Reactor Pressure Vessel (RPV) Rings, and Bearing Races.
  • Size Range: Up to 110 inches (2800mm) outer diameter.

2. Closed-Die (Near-Net Shape) Forging
We utilize precision dies to forge complex geometries with minimal machining allowance, reducing material waste for expensive superalloys.

  • Applications: High-pressure Nuclear Valve Bodies, Turbine Buckets, and Structural Brackets.
  • Materials: Inconel 718, Waspaloy, Titanium 6Al-4V.

3. Open-Die Forging

For large, custom components requiring extreme strength.

  • Applications: Shafts, Blocks, and heavy Industrial Discs.

Material Expertise: Forging the Unforgeable

Alloy Material Forging Challenge Typical Application
Inconel 718 Narrow forging temperature window (1700°F – 2050°F) Gas Turbine Discs
Inconel 625 High flow stress at temperature Nuclear Pressure Vessels
Waspaloy Extreme resistance to deformation Rotating Aero-Engine Components
Hastelloy X Work-hardens rapidly Combustion Liners & Rings

Value-Added Processing

We don’t just forge; we deliver a finished component.

  • Heat Treatment: Solution Annealing, Age Hardening (AMS 5662/5663 for Inconel 718).
  • Rough & Finish Machining: Turning and milling forgings to final print dimensions.
  • Destructive Testing: Tensile, Impact, and Grain Size analysis to verify AS9100 compliance.

Frequently Asked Questions

Q: Why choose forging over investment casting for Inconel parts?
A: Forging is required when the component faces high cyclic loads (fatigue) or extreme impact stress. While casting is better for complex internal cooling channels, forging provides the ultimate structural strength for rotating parts like turbine discs.

Q: Can ForceBeyond forge Waspaloy and other difficult superalloys?
A: Yes. We have the controlled heating furnaces and high-tonnage presses required to plastically deform high-strength superalloys like Waspaloy and Rene 41 without inducing stress cracks.

Ready to forge stronger, more reliable components?

Stop compromising on grain structure. Whether you need a single prototype ring or high-volume production of closed-die parts, ForceBeyond delivers the metallurgical integrity required for aerospace and nuclear applications.

 

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Sources

Our Internal Resources for Die Casting, Investment casting, Forging and Sand Casting