Guide to the development of customized forged products

The development of customer-specific forged products can be a real challenge - standard solutions are often not sufficient to meet the individual needs of different industries.

Whether special dimensions, borderline mechanical properties or special operating conditions - the requirements for forged products are diverse and often extreme.

Breitenfeld has specialized in successfully implementing such complex projects. In this article, we show how we develop individual forging solutions step by step to meet even the most demanding customer requirements.

1. initial contact and analysis of the request

Making contact and first steps

At Breitenfeld, the development process for a customer-specific forged product begins with an in-depth analysis of the customer's inquiry. The responsible sales employee clarifies the requirements in close cooperation with the quality department to ensure that all technical and product-specific requirements are feasible.

Important information for the feasibility check

The following data is required to check feasibility:

• Desired material
• dimensions
• Heat treatment condition
• Quantity required
• Desired delivery time

This information is crucial in order to avoid delays and create a reliable basis for the feasibility analysis. If necessary, special specifications of the (end) customer or certifications are also taken into account.

Analysis of the requirements

The specific requirements for the forged product, in particular the chemical composition and mechanical properties such as tensile strength, hardness and toughness, are examined in detail. Any approvals for specialized markets are also analyzed and checked to see whether they already exist or need to be applied for.

2. specifications and necessary documents from the customer

Technical specifications

Breitenfeld requires precise technical specifications for the development of a customized forged product:

• Material specification with chemical analysis
• Mechanical properties such as tensile strength and hardness
• Special requirements such as temperature or corrosion resistance

In addition, it is determined which test methods are required, such as ultrasonic testing or dye penetrant testing, in order to meet the high quality requirements.

Communication in the event of unclear requirements

If requirements are unclear, Breitenfeld relies on direct communication via team meetings with the customer and the quality department. This promotes rapid clarification of open questions and helps to avoid misunderstandings.

Additional documents

If necessary, information on the areas of application of the product or specific certifications can also be requested. This is particularly important in safety-critical industries such as medical technology, aviation and aerospace, the food industry and high-pressure technology.

3. the internal process for developing the forged product

In-house steps and cooperation between departments

After compiling all the relevant data, the Forging Quality Department carries out a feasibility study to check the requirements for the chemical and mechanical properties of the material. If there are specific questions regarding forgeability or production, the plant management and the plant metallurgy department are consulted.

After a positive review by all departments, the project is approved and transferred to production. In the event of risks, the management decides whether to continue with the project.

Customer involvement in the development process

During the development process, the customer remains regularly informed and is involved in important decisions to ensure that the solution precisely meets the requirements.

4 Technical limitations and feasibility limits

Technical limitations

In certain cases, technical or material-related limitations can affect the implementation, for example, larger block formats have poorer solidification behavior, which is why segregations can occur that impair product quality. Alternative processes such as the remelting process (ESR or VAR) can be used here to achieve higher purity and better mechanical properties.

Communication and alternatives

If technical limits are reached, Breitenfeld communicates this openly and suggests alternative production processes or materials. Economic aspects such as the profitability of alternative processes are also taken into account.

5 Successful projects and application examples

Successful solutions for specific requirements

Some successful projects illustrate Breitenfeld's ability to develop customized solutions:

• A particularly large remelted hot work steel ingot (ED 1200, just under 32 tons) was manufactured for a customer who had previously been unable to find a suitable supplier. This starting ingot was absolutely essential for the intended dimensions.
• A safety sheet with special dimensions was developed in the automotive industry that met both the mechanical requirements and the economic specifications.

6. time frame and project planning

Duration of the development process

The development time depends on the complexity of the project and can be completed within five days for materials that have already been tested. For more demanding projects with internal tests, the development time can be several weeks.

Factors influencing the project duration

Factors that influence the project timeframe include the availability of raw materials, specific approvals and the need for internal testing. Breitenfeld informs the customer of potential delays at an early stage in order to develop solutions in good time.

7. cost framework and price range

Cost estimation and pricing

The cost of developing customized forged products varies depending on raw materials, testing requirements and production processes. Order quantity also plays a role, with long-term projects often offering more scope for cost optimization.

Additional cost items

Additional costs may arise from external testing or certification. Breitenfeld often contributes to these costs in long-term projects in order to strengthen cooperation.

Conclusion: Customized forging solutions

Breitenfeld Edelstahl AG offers customized forged products that are precisely adapted to the customer's specific requirements. The structured, highly communicative process and the close involvement of the customer guarantee the successful implementation of even complex projects. Interested parties with special requirements for forged products can rely on Breitenfeld to always develop the best possible solution.