Open-die ring forging: Maximum flexibility for demanding projects

In safety-critical industries such as aerospace, energy technology and special machine construction, the highest quality and flexibility requirements are standard.

For technical decision-makers and purchasers, comprehensible material properties, reliable delivery performance and efficient solutions for small series or special formats are particularly important.

This is precisely where open-die ring forging at Breitenfeld offers decisive advantages.

Why open-die ring forging? A real procurement advantage

Open-die ring forging is predestined for complex geometries, small to medium quantities and demanding materials where standard processes such as ring rolling reach their limits.

Breitenfeld uses this process specifically to reliably meet special requirements, even with challenging alloys.

Advantages for technical decision-makers and purchasers:

• Flexible batch sizes: economical from single pieces to small series, no minimum purchase pressure
• Freedom of geometry: variable diameters, heights and cross-sections - even if changes are required at short notice
• Broad material portfolio: from high-alloy structural steels to high-temperature, corrosion-resistant special steels

Dimensions at Breitenfeld

• Outer diameter up to 1,300 mm*
• Height up to 450 mm*
• Single piece weights up to 1,000 kg *
  *max. specifications depend on the ratio of ID to OD to height and weight as well as the material

In contrast to classic ring rolling, the free-forming process does not require any costly tool adjustments - which makes the process particularly economical for variable projects.

The rings are manufactured from steel blocks produced in-house, which ensures consistent traceability and reproducible quality.

Technical highlights:

• Machining of alloys that are difficult to form (e.g. martensitic steels, high-temperature special materials)
• Optimum microstructure and fiber flow for safety-critical components
• Precise temperature control and continuous process monitoring

Focus on quality assurance:

• Ultrasonic and fiber flow testing
• Dimensional accuracy checks by experienced forging teams
• Documented test reports - available for all common norms and customer standards

Economic efficiency and delivery performance

• Cost and planning benefits:

  • No tool costs for new geometries
  • Reduced lead times for development projects
  • Flexibility for short-term requests and special materials
  • Material efficiency through targeted pre-size calculation

Delivery times:
Short, project-dependent lead times thanks to high in-house production depth. No dependence on external suppliers of primary materials.

Applications, industries and practical examples

Core industries:
- Aviation: structural components
- Energy technology: generator rings, steam turbine components
- Mechanical engineering: Gear and rolling bearing rings

Practical example:
Ten different rings were manufactured for an aviation customer based on specific material specifications (e.g. high-speed steel 1.3343, 60-64 HRC), including complex heat treatment and complete test protocols - all in small batches, flexibly and on time.

Transparency and security for purchasing

All production steps - from steel production and forging to final testing - are carried out in-house at Breitenfeld. This guarantees

• • Complete traceability (batch to component)
  • Maximum safety and documentation for technical approvals and audits
  • Costing certainty thanks to transparent processes and early project support

Market position and further development

Breitenfeld is one of the few suppliers in Europe to offer a combination of in-house steel production (including ESR and VAR remelting technology) and highly flexible open-die forging.

Investments in larger ring dimensions, new forging presses and the digitalization of the process chain are already planned - for even greater performance and adherence to deadlines.

Conclusion and contact

Open-die ring forging at Breitenfeld enables technical and economical solutions where standard processes reach their limits.

For technical decision-makers and purchasers, this offers a clear competitive advantage for demanding projects.

 

Feel free to contact us - our team of experts is always at your disposal.