Forged Disc
Weight from 20 kg up to 180 tons, with a maximum diameter of 4,500 mm. All provided with certification and, if required, a (customer-specific) specification.
Forged discs
The right disc, in the right grade
Forged discs are often chosen for their superior homogeneity and specific mechanical values/requirements that can be achieved with open-die forging. Additionally, certain diameters are no longer available from stock, which we can then supply to customer specifications. This is frequently requested for specific applications such as equipment manufacturing and the turbine, offshore, valve, aerospace, hydraulic, maritime, and (petro)chemical industries.
Execution
From rough forged to fully machined
Rough forged
Direct from the forging press, heat-treated, and with extra material on the diameter and thickness. Ideal if you are turning the disc to size in-house.
Proof-machined
Both faces and the circumference are smooth-turned. This allows the disc to be ultrasonically tested before you perform the final machining yourself.
Fully machined
Finished according to your drawing, for example, into a tubesheet or turbine impeller. The disc comes with a certificate and is ready for installation.
Process
How a forged disc is created
The input weight is calculated and sawed from the ingot/billet, then brought to the required temperature in the furnace for forging. We then forge it into the desired disc, as close as possible to the final dimensions. This is followed by heat treatment; test pieces are then taken, and the part is proof-machined with a UT test and, if necessary, fully machined according to the customer's drawing.
Applications
For the most demanding industries
Tubesheet
Disc with a small bore
Turbine impeller
Equipment Manufacturing
Offshore
Aerospace
Our Approach
Your partner in forged discs
What is the disc intended for?
Is it for a tubesheet, a turbine impeller, or another pressure-resistant component? Based on the application, we provide advice on material, diameter, and thickness.
Defining dimensions and quality
We determine the diameter, thickness, any potential bore, heat treatment, and certification together. We then verify whether the disc can be forged in this size and grade.
Quote for your disc
We will provide a quote for your disc including price and lead time. Questions regarding, for example, pressure-resistant applications are discussed in advance.
From forging press to delivery
We monitor progress during forging and testing until the disc is delivered to you with its certificate.
Material Grades
Forged discs in almost any grade
Forged discs are often chosen because of the specific diameters and heights that can be achieved. Because we use open-die forging, no mold is required, and we can offer single pieces. Furthermore, every disc is tested separately, guaranteeing 100% traceability and highly reliable quality. We can offer these discs in nearly all material grades.
Frequently Asked Questions
Everything about forged discs
What is the maximum diameter and maximum weight of a forged disc?
The maximum diameter of the forged disc is 4.5 meters, and the maximum weight is 180 tons per piece. This means a forged disc can be supplied in very large dimensions. Both the height and weight are suitable for applications where standard bar material is insufficient.
In which material grades do you supply forged discs?
We can offer forged discs in nearly all material grades. Depending on the application and technical requirements, options include alloy steels, stainless steel, and nickel alloys. The material choice is tailored to the desired properties, standards, and any customer-specific specifications.
What is the difference between a forged disc and rolled material?
The difference between a forged disc and rolled material lies partly in the production method. By using open-die forging, the homogeneity of the material is better guaranteed. Additionally, each disc is tested separately, and the material can be produced according to customer-specific requirements if necessary. This allows the material to be tailored to specific applications.
What is open-die forging and why is it chosen for discs?
Open-die forging is a forging technique where the workpiece is shaped by a forging press without the metal being forced into a closed die mold. The shape is created step-by-step by repeatedly rotating, moving, and working the material under the press or hammer—hence the name "open-die," as opposed to closed-die forging, where the metal is pressed into a pre-formed negative die.
Why this is chosen for discs:
No expensive dies required: closed-die forging requires the creation of a costly steel die first. This is only cost-effective for large series. For discs (often small series, custom work, or very large dimensions), open-die forging is much more cost-effective.
Suitable for large dimensions: discs up to several meters in height and large diameters simply cannot be pressed in a die; the press capacity and die size would become unfeasible. Open-die forging can process very large workpieces using relatively compact tools.
Flexibility in dimensions: you can easily vary the height, diameter, and stepped transitions without creating new tools for every variant.
Excellent material structure: through repeated kneading and compaction during open-die forging, the grain structure of the steel becomes finer and more evenly distributed, which significantly improves mechanical properties (toughness, fatigue strength). This is crucial for heavy-duty components.
Suitable for small to medium series and prototypes
Do you supply forged discs rough, proof-machined, or fully machined?
We primarily supply forged discs proof-machined, so that we can at least perform the ultrasonic testing. Additionally, we can offer fully machined forgings, entirely according to the customer's drawing and requirements. In this way, both proof-machined and fully machined versions of forged discs can be supplied, depending on the desired execution.
What diameters are possible for a forged disc?
Diameters up to 4,500 mm are possible for a forged disc. This allows for the delivery of very large discs. This wide range of diameters makes it possible to use forged discs for various industrial applications where large dimensions are required.
Do you apply heat treatment and is this included as standard?
All discs are heat-treated, at least according to the standard associated with the material grade. Additionally, we can perform specific heat treatments according to customer-specific requirements. This allows the heat treatment and execution to be aligned with the applicable material grade and any additional customer requirements.
Is a forged disc suitable for critical applications, such as in equipment manufacturing, the energy sector, or the aerospace industry?
Yes, open-die forging is particularly suitable for critical applications within the energy, aerospace, turbine, maritime, and (petro)chemical industries, as well as equipment manufacturing. This is due to the specific material structure, dimensions, and requirements demanded by these applications. A forged disc can therefore be used for applications where specific demands are placed on the material and the product.
What is the usual lead time for forged discs?
The lead time for forged discs depends on the weight and dimensions of the disc. In proof-machined execution, we can deliver certain discs within 6 working weeks. For fully machined discs, the lead time is 8 to 10 working weeks. The exact lead time therefore depends on the execution, weight, and dimensions of the disc in question. Occasionally, we can also deliver certain grades/diameters very quickly from stock.
Do you supply single pieces or small series of forged discs?
Yes, open-die forging is specifically used for single pieces and small series because it does not require investment in an expensive die. Because we use open-die forging, we can offer a forged disc as a single piece. This makes open-die forging suitable when specific dimensions or executions are needed and a large series is not required.
Request your quote without obligation
Provide the diameter, thickness, and grade of the disc, along with the number of pieces. We will check what is feasible and respond quickly.
Always with certification
Single pieces and small series
Customer-specific specifications
Diameters up to 4,500 mm