_MNL_53-2005.pdf

Steel Forgings:Design,Production,Selection,Testing,and Application Edward G.Nisbett ASTM Stock No.MNL53 INTERNATIONAL Standards Worldwide ASTM International 100 Barr Harbor Drive PO Box C700 West Conshohocken,PA 19428-2959 USA Printed in U.S.A.Library of Congress Library of Congress Cataloging-in-Publication Data Nisbett,Edward G.Steel forgings:design,production,selection,testing,and application/Edward G.Nisbett.p.cm.ASTM Stock No.MNL53.*ISBN 0-8031-3369-3 1.Steel forgings.I.Title.TS320.N59 2005 672-dc22 2005020481 Copyright 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,without the written consent of the publisher.Photocopy Rights Authorization to photocopy items for internal,personal,or educa-tional classroom use,or the internal,personal,or educational classroom use of specific clients,is granted by ASTM International provided that the appropriate fee is paid to the Copyright Clearance Center,222 Rose-wood Drive,Danvers,MA 01923;Tel:978-750-8400;online:http: Society is not responsible,as a body,for the statements and opin-ions expressed in this publication.Printed in Bridgeport,NJ September 2005 Foreword THIS PUBLICATION,Steel Forgings:Design,Production,Se/ec-tee A01 on Steel,Stainless Steel and Related Alloys.The author tion,Testing,and Application,was sponsored by ASTM Commit-is Edward G.Nisbett.Contents Chapter 1:Chapter 2:Chapter 3:Chapter 4:Chapter 5:Chapter 6:Chapter 7:Chapter 8:Chapter 9:Introduction:Why Steel Forgings?.1 Why Use Forgings?.5 Steel Plate.5 Hot Rolled Bar.5 Steel Castings.5 Steel Forgings.6 Effect of Steel Making.15 Steel Refining.15 Ladle Refining Furnace.16 Vacuum Degassing.16 Steel Cleanliness and Inclusion Shape Control.19 Forging Ingots.20 Vacuum Arc Remelting.20 Electroslag Remelting.21 Ingot Mold Design,Ingot Production and Segregation.22 Forging Stock.22 Types of Forging.24 Open Die Forging.24 Closed Die Forging.25 Extrusions.25 Rotary Forging Machines.26 Ring Rolling.27 Forging Reduction.27 Heating for Forging.32 Heat to Forge Furnaces.32 Reheating.33 Induction Heating.33 Post Forge Practices.34 Machining.36 Grinding.37 Heat Treatment.40 Annealing.40 Micro-Alloyed Forgings.40 Carbon and Alloy Steel Forgings.40 Heat Treatment Equipment.41 Furnaces.41 Batch Furnaces.42 Horizontal Furnaces.42 Vertical Furnaces.42 Continuous Furnaces.43 Induction Heating.43 Controlled Atmosphere/Vacuum Furnaces.43 Cooling/Quench Facilities.43 Liquid Quenching.43 Water Quenching.43 Oil Quenching.45 Polymer Quenching.45 Polymer Concentrations.45 Spray Quenching.46 Alternate Heat Treatments.46 Heat Treatment Rigging.46 Hot Rigging.46 Cold Rigging.48 Tempering.50 Chapter 10:Mechanical Testing.53 Hardness Testing.54 Tension Testing.55 Impact Testing.57 Fracture Toughness Testing.57 Fatigue Testing.57 Chapter 11:Nondestructive Examination.59 Surface Examination.59 Visual Examination.59 Magnetic Particle Examination.60 Liquid Penetrant Examination.61 Volumetric Examination.62 In-Service Inspection.65 Chapter 12:Surface Treatment.66 Direct Hardening.66 Nitriding.67 Gas Nitriding.68 Ion Nitriding.69 Carburizing.69 Salt Bath Treatments.70 Cold Working.71 Chapter 13:Manufacturing Problems and Defects.72 Base Material Choice.72 Ingot Defects.72 Ingots Size and Choice.74 Billet/Bloom Size and Source.74 Heating for Forging.75 Induction Heating.76 Forging Operations and Sequence.76 Machining.76 Post Forge Handling/Heat Treatment.76 Chapter 14:A Word about ASTM International,Committee A01 on Steel,Stainless Steel,and Related Alloys,and General Requirement Specifications for Forgings.78 Writing Standards.78 ASTM International Steel Forging Standards.78 General Requirements Specifications.79 General Requirement Specifications for ASTM Steel Forging Specifications.79 A 788-04 Steel Forgings,General Requirements.79 Specification A 961/A 961M-04a Common Requirements for Steel Flanges,Forged Fittings,Valves,and Parts for Piping Applications.82 Chapter 15:Steel Forgings for the Fittings Industry.84 A 105/A 105M-03,Carbon Steel Forgings for Piping Applications.84 A 181/A 181M-01,Carbon Steel Forgings for General Purpose Piping.85 A 182/A 182M-04,Forged or Rolled Alloy and Stainless Steel Pipe Flanges,Forged Fittings,and Valves and Parts for High Temperature Service.86 A 350/A 350M-04a,Carbon and Low-Alloy Steel Forgings,Requiring Notch Toughness Testing for Piping Components.86 A 522/A 522M-04,Forged or Rolled 8 and 9%Nickel Alloy Steel Flanges,Fittings,Valves,and Parts for Low-Temperature Service.88 A 694/A 694M-00,Carbon and Alloy Steel Forgings for Pipe Flanges,Fittings,Valves,and Parts for High-Pressure Transmission Service.89 A 707/A 707M-02,Forged Carbon and Alloy Steel Flanges for Low Temperature Service.89 A 727/A 727M-00,Carbon Steel Forgings for Piping Components with Inherent Notch Toughness.89 A 836/A 836M-02,Specification for Titanium-Stabiliz