Custom Forged Discs

Western of Texas Forge & Flange custom forged discs are manufactured using a similar forging process as custom forged rings, but they follow a slightly different procedure due to their distinct shape and application requirements. Forged discs can be customized to match specific flange dimensions and pressure ratings, making them versatile for a range of applications. Here is an overview of our manufacturing process for custom forged discs and their use in conjunction with forged flanges.

Manufacturing Custom Forged Discs

Material Selection and Preparation

• The manufacturing process begins by selecting high-quality raw materials like carbon steel, stainless steel, aluminum, or special alloys, depending on the desired properties of the disc.
• The raw material is cut into a cylindrical billet or ingot and then heated to a specific temperature to increase its malleability.

Initial Forging

• The heated billet is placed in a press and forged into a rough disc shape. During this step, the billet is compressed between two dies to shape the material into a flat, circular form with the desired diameter and thickness.
• The forging process can be done using open-die forging (for larger discs) or closed-die forging (for smaller, precision discs).

Upsetting and Flattening

• Depending on the desired thickness, the disc may undergo upsetting, a forging technique that increases the thickness by compressing the material further.
• The disc is then flattened to ensure uniform thickness and surface quality.

Heat Treatment

• The forged disc is subjected to heat treatment processes like annealing, normalizing, or quenching and tempering to achieve the desired mechanical properties such as hardness, ductility, and toughness.

Machining and Precision Shaping

• After forging and heat treatment, the disc is machined to achieve the final dimensions, surface finish, and tolerance specifications.
• Additional operations like drilling, boring, or tapping may be performed if the disc is designed to accommodate bolt holes or grooves.

Surface Finishing

• Depending on the end application, the disc may undergo surface finishing processes such as grinding, polishing, or coating to improve its surface quality, corrosion resistance, and aesthetic appearance.

Quality Control

• The final forged disc is thoroughly inspected for dimensional accuracy, mechanical properties, and surface defects using non-destructive testing methods like ultrasonic testing or radiography.

Application and Use of Forged Discs with Forged Flanges

Forged discs are often used in conjunction with forged flanges in various industries, including oil and gas, chemical processing, power generation, and mechanical equipment manufacturing.

They also serve as components in valve assemblies and pressure vessel closures and can be welded or bolted to forged flanges to create a secure and pressure-tight seal for high-pressure and high-temperature environments.

Benefits of Using Forged Discs and Flanges Together

Strength and Durability

• Both forged discs and flanges offer high mechanical strength, resistance to fatigue, and long service life, making them ideal for critical applications.

Seamless Integration

• The precise dimensional tolerances achieved during the forging process ensure that forged discs fit seamlessly with flanges, providing leak-proof and secure connections.

Custom forged discs and forged flanges are crucial components in industries that demand reliability, high performance, and safety. Their combined use provides a strong and secure connection system for a wide variety of applications, particularly where high pressures, temperatures, and mechanical loads are involved.

Western of Texas Forge & Flange has the expertise and background necessary for forging custom industrial products like rings, discs, blocks, cylinders, tubesheets, and valve bodies. This encompasses various essential engineering and manufacturing procedures aimed at guaranteeing that the end product adheres to exact mechanical and dimensional specifications.