Success through integrity - independentforgings.com - Independent Forgings and Alloys Ltd
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
success through integrity
Independent Forgings and Alloys Ltd
Victoria Forge, Livesey Street, Sheffield S6 2BL UK
independentforgings.com
From the deepest oceans Success Through Integrity
to outer space...
Wherever you find critical engineering applications, Our vision of Success Through Integrity is supported by our core values
that’s where you’ll find our high integrity forgings. • Working safely - safety is a priority in all that we do, both
the safety of all on our site and providing a safe product.
Formed in 2001, IFA has evolved through growth and
strategic investment into a unique 670,000 ft2 • Teamwork - by working respectfully together in teams
single site manufacturer of semi-finished high across our business, we build great relationships,
integrity components with open-die radial, press, recognise outstanding contributions and create the
hammer & ring rolling and closed-die extrusion, environment for our highly skilled workforce to support
drop stamp and blade forging. our customers in meeting their requirements.
• Always looking for improvement - our team are excellent
The forge is fully integrated with our on-site at what they do and are constantly working to
material stockholding centre, heat-treatment improve our processes.
facility, CNC machining centre, inspection
centre and a mechanical & metallurgical
test laboratory.
Our global markets
Through our extensive forging capabilities and
Commercial Aerospace
processes, we take responsibility to fulfil our customer’s
requirements in full, from ingot/billet and forging through Oil & Gas
to fully tested and released machined products. Powergen/IGT
Industrial Processing
Independent Forgings and Alloys Ltd Civil, Marine, Nuclear, Motorsport
Victoria Forge, Livesey Street, Sheffield S6 2BL UK
independentforgings.com Tel: +44 (0) 114 234 3000 Fax: +44 (0) 114 234 0261
Military & Defence
Email: sales@independentforgings.com
Our Process Flow
GFM Radial Forging
Heavy Press Forging LASCO Press success through
success through integrity
integrity
Finished Products
Inspection
Global Distribution
Ingot
Ring Rolling
Heat Treatment Machining
Gravity Drop Stamp
Billet
Testing
Hammer Forging
Small Blade Forge
Press Forging Hammer Forging
Our 1500 tonne fast acting draw-down hydraulic press is fed IFA operate 1 & 2 tonne forging hammers which give
by mobile manipulators for rapid transfer of material from 10 us a high level of flexibility in the production of:
available gas furnaces.
• Bars
This facilitates a very high level of flexibility for
• Rings
production campaigns.
• Blanks
Maximum material able to be forged: • Boss Blanks
• Planks
6 tonnes: ingot conversion to billet • Squares
and bars
• Bespoke NNS
4.5 tonnes: blocks, blanks,
punched blanks, discs. Our annnual capacity exceeds 30,000 forgings
4.0 tonnes: rings, bossed blanks produced in weights from 5kg to 150kg.
GFM Radial Forging Ring Rolling
Our GFM SX26 radial forge gives us the capability to manufacture custom With our horizontal and vertical ring rolling capacity,
long forged products as round, square, rectangular, hexagonal we can produce rings up to 2500mm diameter, 720 mm
and multi-section shafts. deep & 2500kg weight.
A minimal material allowance is normally only required to protect the final Our 40 & 300 tonne mills are fed by gas fired furnaces,
dimensions of finished parts thus saving material and machining costs. ring handling manipulators, a 1000 tonne hydraulic
press, hammers and ring expanders.
Section Minimum Maximum
Standard shifts are capable of producing 17,250 close
Rounds 48mm 250mm tolerance rings and cylinders per year and capacity is
Squares 50mm 170mm always available, as we can increase the number of shifts
Flats (W) 50mm 195mm we operate.
Flats (T) 20mm
LASCO Press Forging Gravity Drop Stamping
IFA’s 1750 tonne LASCO Press Forge enables us to produce the We operate the following gravity drop stamp hammers:
following in sizes of 150 - 1000mm length, 50 - 375mm diameter,
and in weights of 2 - 250 kilos, dependent upon material 1.5 tonne Closed-Die Hammer
and complexity: 2.5 tonne Closed-Die Hammer
4 tonne Closed-Die Hammer
• Housings
• Casings For the production of
• Liners • Bearings
• Closed and open tubes • Gears
• Spindles • Shafts
• Shafts • Actuators
• Housings
• Valves
Sizes: 25 - 300 mm deep, 100 - 400 mm diameter
Weights from 0.25 to 75 kilos.
Small Blade Forging Forging Simulation
Our small blade forging cell provides the following capabilities: IFA assumes the responsibility to fulfil our customer’s requirements in full. We use forging
simulation software to create new parts as 3D models in order to plan and refine the forging
700 tonne Maxipress operation, before we make tooling or use material to produce test forgings. Simulation of
300 tonne Hydraulic Press forging processes solves the following technological requirements:
2000 tonne Crank Press
900 tonne Upsetter • Stress-strain state calculation and prediction of material flow in full billet volume during
1600 tonne Upsetter execution of forging operations
• Prediction of structure quality after forging and estimation of surfaces and inner defects
Production includes • Finding optimal shapes for forging tools
• Single and double ended compressor blades • Finding optimal forging regimes: heating, rotation and/or axial movement between blows
• Vanes and turbines. • Developing processes and determining requirements of heating between operations
• Small rings and complex shapes
Simulation improves the efficiency of a technological process by:
Sizes: 25 - 300mm length • Reducing wasted material
Weights: 5 - 5000 grams • Increasing the durability of the tooling
• Providing favourable microstructure of the forged part (fibrous structure), to increase its operational qualities
• Providing optimal temperature profile of heating, forging and heat treatment to get favourable microstructure
Heat Treatment Machining
Accredited to AMS2750 and ISO10423, our dedicated NADCAP heat treatment Our modern 10,000ft2 facility houses our machining centre, where
facility includes 8 gas-fired furnaces fed by 2 rail bound charging machines with forged parts are machined to near net shape, or according to customer
water and oil quench tanks and full temperature control and monitoring features requirements.
on all units.
Finishes range from proof machining to inspection profiles or precision
Charges of up to 6 tonnes quenched, and 10 tonnes air/furnace cooled, long bars close tolerance machining.
up to 22′/ 6.7m can be annealed and warm straightened. Several smaller furnaces
cater for small loads and low temperature treatment, with a temperature range IFA have invested in a suite of 5-axis CNC lathes, vertical borers, mills
from 420 - 1230°C. and long bar lathes, able to machine parts up to 2200mm diameter,
3300mm length and 750mm height.
• Annealing
• Normalising
• Hardening / Tempering
• Stress Relieving
• Solution Treatment
• Ageing and Precipitation Treatments
Testing & Inspection Hirework
Our own modern, purpose built test laboratory and team of skilled technicians and operators, means Our Hirework Sales Division offers a fast and efficient conversion of
we can test the materials we produce to ensure strict compliance to customer requirements. customer owned materials.
Our Press and Hammers can forge bars, blocks, rings, blanks and near net
shape forgings in weights from 1kg up to 6000kg. Our GFM Radial Forge will
Mechanical Metallurgical NDT inspection
convert any slow moving or redundant stock or eliminate long mill lead time
Room Temperature Tensile Microstructure Operator qualified to SNT-TC-1A & PCN Level III
issues and produce flats, rounds and squares with machining quality “as
Elevated Tensile (300 – 800°C) Macrostructure Contact ultrasonic examination
forged” surfaces. Our Ring Mills can roll rings up to 2500mm OD.
Charpy Impact (-80 – 200 °C) Grain Size Positive Material Identification (PMI) testing
Brinell Hardness (HBW 10/3000) Inclusion Count/Microcleanness Dye Penetrant Inspection (DPI) of machined products.
Further heat treatment,
Rockwell Hardness (HRC & HRB) Alpha Case Depth Measurement Magnetic Particle Inspection (MPI) of machined products
machining, testing and
Vickers Hardness (HV10 & HV30) Volume Fraction CMM Dimensional on components up to 600mm diameter
inspection services can
Experienced Visual examination of finished products.
also be offered.
Component marking.
Specimen heat treatment from 350 to 1150°C
Quality Approvals A fully integrated forging service
Heat Treatment Test Laboratories
High performance alloys based on our strategy and customer needs are sourced as
forging ingot and billet stock from approved mills. This material is then processed GFM Radial Forging
Press Forge
through our open and closed die hot working units against customer requirements.
Furthermore, our investment in quality approvals and robust management and Open Die Forge Inspection Ring Rolling Cell
operating systems ensure your reputation is not at stake with your customers when
you supply them components produced from our forgings, and we take responsibility to
supply your requirements in full.
Strategic Inventory Precision Blade Forge Open Die Hammers
Titanium Nickel Alloys Stainless Steel Steel Aluminium
IFA hold the following accreditations and approvals:
6-2-4-2 625 K500 253MA 416 4340 7075 Machining Facility
• NADCAP - AC7140 Metallic Materials Manufacturing 6-2-4-6 718 400 316L 310 8630 7049
• NADCAP - AC7101 Materials Testing Laboratory 6AL4V 725 617 321 18-18 General 7050
low alloy
• NADCAP – AC7114 Non Destructive Testing
TI230 80A WAS 410 M153 1020 L77
• NADCAP – AC7102 Heat Treatment TA550 825 188 FV520B FV448 1040 L168
Gr 23 6AL4V R41 625 PLUS M152 M250 508M
• NADCAP – AC7108 Chemical Processing
ELI HX 909 A286 M300 4330
• LR AS9100 Rev D/ISO 9001: 2015 Quality
Gr 1 25 PE11 17-4PH M350 53
Precision Forge Inspection Offices LASCO Press Forge
• LR ISO 14001: 2015 Environment Gr 2 75 105 15-5PH XM19 440C
• LR ISO 45001: 2018 Safety Gr 3 230 HS 13-8MO X20Cr13 B16 NDT Inspection Tooling Manufacture Drop Stamp Hammers
Gr 4 C263 800 347 450 CBS50NIL
• Lloyd’s Register of Shipping
Gr 7 X750 800HT 304L F51 HYKRO
• UKAS - ISO/IEC 17025:2017 Testing & Calibration Laboratories
With a heritage that goes back almost 250 years,
Gr 9 600 901 316 18-18-2 4145
IFA is today actively building on its tradition of
Gr 12 technical excellence, innovation and flexibility.
success through
success through integrity
integrityYou can also read
