August 2025 Volume 7

OFFICIAL PUBLICATION OF THE FORGING INDUSTRY ASSOCIATION | FORGING.ORG | AUG 2025

The Latest Trends in Forging Materials & Tooling Technology Page 14

Preventing Forging Die Failure Page 20 Titanium Forging: Commercial and Technical Landscape Page 25

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FIA MAGAZINE | AUGUST 2025

LETTER FROM THE EDITOR

LETTER FROM THE EDITOR

Forge Fair 2025 – A Resounding Success

Looking Ahead FIA’s mission remains clear: to help North American forging companies compete, grow, and lead. Through technical training, networking, data-driven insights, and strong advocacy, we are committed to supporting the long-term success of our industry. Leadership may evolve, but FIA’s direction remains focused. In the years ahead, no matter who is at the helm, we will continue to expand our impact—as a champion for innovation, a trusted source of education, and a strong voice in public policy. We will strengthen our relationships with government leaders, help members embrace emerging technologies, and raise the global profile of North American forging. Most importantly, FIA’s work is driven by you—our members and partners. As long as we move forward together, we will continue to build a stronger, more competitive industry. Best Regards,

Since our May issue, FIA has executed multiple events, most notably Forge Fair 2025. With over 1,620 attendees and 152 exhibitors, it was one of the most impactful gatherings in our industry. Thank you to our dedicated FIA staff, exhibitors, speakers, and attendees who made it such a success. A show recap is available on page 52.

Searching for FIA’s Next President & CEO While I’ve greatly enjoyed serving as Interim President & CEO, the search is actively underway to identify FIA’s next leader. The Board has retained Association Strategies Inc. to lead the process and is currently accepting applications. Details about the position and how to apply can be found on page 51. Standing Up to Unfair Trade Practices The issue of global trade fairness remains a top priority. FIA continues to engage with policymakers, legal counsel, and coalition partners to address dumping and advocate for strong Section 232 tariff enforcement. In this issue, don’t miss perspectives from Bret Halley, FIA Board and Public Policy Committee Member (page 74), Omar Nashashibi in the Washington Update (page 6), and international insight from Euroforge’s Tobias Hain (page 45). Spotlight on Innovation in Materials and Tooling In this issue’s cover story, we take a deep dive into the latest trends shaping forging materials and tooling technology. With insight from industry leaders at Universal Stainless, Metallus, Gemini Group, and EST Tool, the article explores the growing demand for ultra-clean alloys, smarter die systems, and collaborative sourcing strategies. From digital integration to advanced surface treatments, the evolution of materials and tooling is accelerating—and this feature showcases how North American companies are stepping up to meet the challenge. Don’t miss “The Latest Trends in Materials and Tooling Technology” on page 14.

Angela Gibian, CAE Interim President & CEO Forging Industry Association

Editorial Staff

Board of Directors

Antonio Alvarez Robert R. Bolin Robert Brodhead

James D. Kane Jeff Krueger Louis Philippe Lapierre

PUBLISHER Angela Gibian angela@forging.org ASSOCIATE EDITOR Amanda Dureiko amanda@forging.org

DESIGN Lorean Crowder lorean@forging.org

CHAIRPERSON Jeffrey T. Jones VICE CHAIRPERSON Paul A. Spitz

Mark Derry Bret Halley

Jose Lozano Matt Natale

FIA MAGAZINE | AUGUST 2025 3

CONTENTS

AUGUST 2025 | VOLUME 7

p. 20

p.25

p. 14

LETTER FROM THE EDITOR 3 Letter From the Editor WASHINGTON UPDATE 6 Forging Growth ENERGY 8 The New Energy Reality 10 Coal Is The New Bridge Fuel EQUIPMENT & TECHNOLOGY 11 Rotary Hearth Furnace for Steel & Alloy Heating 12 A Supplier’s Perspective from the Die Up 14 The Latest Trends in Materials and Tooling Technology 16 Forging Die Wear: Understanding Failures, Extending Die Life 18 What’s Next in Mechanical Forge Press Technology

MAINTENANCE 20 Preventing Forging Die Failure 22 Maintaining your Upsetter Forging Machine AUTOMATION 24 Introducing Semi- and Fully Automated Induction Forging Systems MATERIALS 25 Titanium Forgings – Commercial and Technical Landscape OPERATIONS & MANAGEMENT 30 Temporary or Contract Workers Are Not My Employees, So I Don’t Have to Worry, Right? Not Necessarily. 32 The Paradox of the Invisible Discipline 34 You’re Gonna Need a Bigger Boat: Preparing for Evolving Cyberthreats 36 Reindustrialization: An Idea Whose Time Has Come 38 Powering A Safer And More Sustainable Future 40 Industrial Strength AI INDUSTRY NEWS 44 FIA Interim President & CEO Angela Gibian Named 2025 Progressive Woman Honoree

45 A European Perspective on the State of the Industry 48 Every bit as impactful 51 Forging Industry Association 52 Forge Fair 2025 54 Welcome New Members 55 Recruit New FIA Members & Get Rewarded! 56 FIA Upcoming Events FOUNDATION NEWS 59 FIERF Donor Spotlight: DANGO & DIENENTHAL 60 Forged in Johnstown FORGING RESEARCH 64 Forging Education 68 Forging Futures: Four Workforce Levers Every Shop Can Pull Today 70 A Forging Technology First MEMBERS SPEAK 74 Let’s Keep North American Forging Strong and Competitive AD INDEX 75 August Advertiser Index Begins Search for President & CEO

OFFICIAL PUBLICATION OF THE FORGING INDUSTRY ASSOCIATION | FORGING.ORG | AUG 2025

The Latest Trends in Forging Materials & Tooling Technology Page 14

Preventing Die Failure Page 20 Titanium Forging: Commercial and Technical Landscape Page 25

For advertising contact info@forging.org

FIA Magazine (ISSN 2643-1254 (print) and ISSN 2643-1262 (online)) is published 4 times annually, May, August, November and February by the Forging Industry Association, 6363 Oak Tree Blvd., Independence, Ohio 44131. Telephone: (216) 781-6260. Only (1) copy of the print version distributed at no charge only to members of the Forging Industry Association. Digital version distributed at no charge to qualified individuals. Subscription requests available at www. forging.org. Printed in the U.S.A. Periodicals postage paid in Independence, OH and additional mailing offices. POSTMASTER: Send address changes to Forging Industry Association, 6363 Oak Tree Blvd., Independence, Ohio 44131. Copyright © 2025 by the Forging Industry Association in both printed and electronic formats. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the publisher. The publisher is not responsible for product claims and representations or for any statement made or opinion expressed herein. Data and information presented by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

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FIA MAGAZINE | AUGUST 2025

WASHINGTON UPDATE

FORGING GROWTH What the New Tax Law Means for Your Bottom Line By Omar S. Nashashibi

O n July 4, 2025, President Trump signed into law a major manufacturing investment bill delivering on a promise long championed by the Forging Industry Association: a tax code that puts domestic manufacturing first. After watching trading partners subsidize their industry for decades, this legislation brings permanency and certainty to the tax provisions our industry uses to compete globally. After months of debate, advocacy, and industry pressure from groups such as the FIA, H.R. 1 is now law, and with it comes a suite of tax provisions poised to drive investment, reward domestic operations, and ensure the next generation of manufacturers can take the reins. Our members spoke up. Flew to Washington to lobby on this bill and Congress listened. Now it’s time to put these pro-growth tax tools to work. Tax on R&D Eliminated; Expensing Made Permanent Forgers have long relied on research and development to invest in better processes, improve efficiency, and meet increased demand. The new law FIA lobbied to pass ends the harmful requirement to amortize domestic R&D expenses over five years and restores the ability to immediately deduct these investments retroactive to January 1, 2025. This is a significant win for innovation-driven companies to help them grow and succeed. For smaller manufacturers with less than $31 million in gross receipts, the FIA helped secure an even bigger victory – R&D expensing retroactive to January 1, 2022 – giving these businesses the opportunity to recoup much of the amortized tax payments made over the past three years. The FIA lobbied extensively on this provision to restore and make permanent the expensing of R&D activities to help level the playing field against countries such as China, which offers its manufacturers a super deduction of 175 percent on some eligible R&D expenses. Bonus Depreciation and 179 Expensing: Invest, Modernize, Expand The forging industry is among the most capital intense, requiring our members to spend millions of dollars on their plants, equipment, and machinery. The tax law restores 100 percent bonus depreciation (Section 168) from its current 40 percent rate retroactive to January 2025. Not only does the law restore full and immediate expensing, bonus depreciation is now permanent, allowing businesses to plan their investments rather than rushing to place a machine into service ahead of an upcoming expiration date. New equipment, plant upgrades, and qualifying used assets all remain eligible for immediate expensing. Section 179 expensing also sees a major boost, with the annual limit now locked in at $2.5 million, with a dollar for dollar phaseout after $4 million for qualifying investments. This is an unprecedented opportunity to upgrade presses, invest in next-gen

robotics, or overhaul tooling with upfront tax advantages. For CFOs charting next year’s capital budgets, the directive is clear: you no longer have to defer growth decisions due to uncertainty from Washington. We now have stability to invest today, allowing the opportunity to plan for the future. Section 199A: Relief for S-Corps, LLCs, and Partnerships The majority of manufacturers in the U.S. are structured as a pass-through entity, with the owner paying at the much higher individual tax rate of up to 37 percent. In the 2017 Tax Cuts and Jobs Act, lawmakers made permanent a 21 percent income tax rate for C-Corporations, while allowing for a temporary 20 percent deduction under Section 199A for pass-throughs. The law removes the threat of a tax increase on pass-throughs scheduled for December 31, 2025, and now makes the Section 199A deduction of 20 percent permanent. While C-corporations maintain their 21% rate, this provision ensures S-corps, partnerships, and sole proprietors are not left behind. With many forging operations structured as family-owned or pass-through entities, the Section 199A provision remains a key tool for reducing taxable income and keeping reinvestment capital inside the business. Interest Deduction – Section 163(j): Relief for Growing Companies Capital-intensive manufacturers have struggled under the restrictive EBITDA interest limitation rules that beginning January 1, 2022 could not factor in depreciation or amortization in their deduction calculations. H.R. 1 answers that by restoring the full EBITDA standard, replacing the more restrictive EBIT calculation, and lifting the cap on business interest expense deductions back to 30 percent of EBITDA. This shift improves liquidity for members financing expansions, purchasing equipment, or investing in working capital. For CFOs evaluating financing options, the EBITDA rule means more room to grow without facing punitive tax penalties. Estate Tax: Protecting Family Businesses For family-owned businesses, estate planning and structuring a business transition is not only complicated but can strain familial relations. The makes permanent existing law allowing for individuals to exempt up to $15 million from the estate tax and up to $30 million for those filing jointly. Importantly, H.R. 1 includes indexing to inflation, ensuring these protections don’t erode over time. This ensures founders and family operators can transition ownership without forcing asset sales or triggering estate-tax driven reorganizations. Family businesses can plan for succession with far more confidence than in years past.

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FIA MAGAZINE | AUGUST 2025

WASHINGTON UPDATE

Education and Workforce Development: Investing in the Next Generation Our FIA members tell us that a strong and reliable workforce pipeline remains a top priority. H.R. 1 provides both employers and employees a number of tools to help them invest in careers and a skills-based ecosystem. To support the next generation of skilled tradesmen and women, individuals can now use 529 plans qualified industry credentialing, giving families added flexibility in saving for skills-based education. The law also makes permanent, Section 127 Employer Education Assistance, which allows employers to provide tax-free student loan repayment assistance of up to $5,250 annually. This is in addition to the expansion of Pell Grants to cover short term programs. The Tax Cuts and Jobs Act of 2017 focused more on lowering tax rates, while this law emphasizes investment in domestic production activities that can provide a strategic blueprint for industry-led growth. The Forging Industry Association fought hard for this tax package because it delivers where it counts: reinvestment, growth, and generational continuity. Our members have long correctly recognized that other countries subsidize their manufacturers to give them an upper hand over U.S. industry. This law creates a policy environment where American manufacturers can compete on fairer terms, reinvest faster, and plan longer-term.

Omar S. Nashashibi is the Founder of Inside Beltway, a nonpartisan lobbying and strategic consulting firm in Washington, D.C. Having worked in the nation’s capital for over twenty-five years, Mr. Nashashibi provides strategic consulting services to companies while also lobbying the White House and Congress on behalf of manufacturing, associations, defense firms, nonprofits, and other sectors. He works with policymakers on trade, taxes, environmental and workplace regulations, supply chains, job training and identifying grants and funding to support projects. Having started his career

in Washington D.C. in 1996, Mr. Nashashibi worked for the Office of Management and Budget, a branch of the White House, a large multi-state law firm, and founded a previous lobbying firm in 2005. He graduated from the George Washington University in Washington, D.C., where he studied Political Science and International Affairs. He is based in Washington, D.C., representing the Forging Industry Association. He can be reached at omar@ insidebeltway.com.

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www.forging.org info@forging.org (216) 781-6260

FIA MAGAZINE | AUGUST 2025 7

ENERGY

THE NEW ENERGY REALITY A More Modern, Strategic Approach to Procuring and Managing Power By Nancy Gardner

And, if it is, wouldn’t it be nice to know that change is possible – that you could get so much better at managing energy without adding risk? It’s Time for a Change: Put Energy Auctions to Work for You Energy auctions are one of the best tools available to help you control and manage energy costs. While many CFOs aren’t familiar with the use of auctions as a procurement tool in energy, or may think that their company’s particular circumstances wouldn’t lend themselves well to such auctions, the truth is that this technique is both a proven winner and extremely versatile . In fact, auctions are a pillar of our modern financial system, creating a highly liquid, transparent, safe, and effective environment for transacting trillions of dollars in U.S. debt securities. Let’s take a closer look. The majority of companies still buy energy the old fashioned way. While nearly every procurement decision in the modern enterprise is centralized and digitized, energy is often left up to individual facility managers. Facility managers typically engage the energy market in one of two ways: they either run a procurement themselves, soliciting bids from, at most, a few local suppliers, selecting the one with the best price, and renewing contract after contract with them to minimize the headache of a new procurement; or they engage an analog broker who does a version of the same thing, comparing a few bids via phone or email to help make a selection. There are a number of problems with this “old way” of procuring energy , especially a lack of transparency, competitive vigor, and risk control. Now, what if you could bring your company’s energy load to market with less time and human capital, while receiving bids from several suppliers, so that in a matter of 30-60 minutes you received dozens or hundreds of bids – each bid driving down the price! – for your energy contract across multiple products and terms? And what if you could see all of these bids in real time, choose the result you liked best, and retain a digital record of all the bidding? When you buy energy the old way, your organization has to take someone’s word for it that they ran a good procurement. When you leverage the power of online energy auctions, you create a competitive market that puts you in control . Suppliers battle each other in real time, shedding margin to win your business .

T he U.S. is in the midst of a once-in-a-century power grab that has implications for every forging company. After a decade of relatively stable electricity and natural gas prices, the cost of energy has begun to rise precipitously as data centers – fueled by the AI and crypto-mining revolutions – drive energy demand through the roof. Consider these facts: • In its latest Short-Term Energy Outlook, the U.S. Energy Information Administration (EIA) forecast annual energy consumption in 2025 and 2026 will surpass the all-time high set in 2024. • Commercial and Industrial companies in PJM, which serves 65 million customers across thirteen states, are facing an overall increase in their electric bills of 12-22% based on a 750% weighted-average increase in capacity charges (a levy users pay on their monthly bill to ensure access to power). • During a recent heat wave (June 2025), New York City saw wholesale electric prices selling for nearly $2,400 per MWh ($2.40 per kWh!) compared to a normal summer day of $50-70 per MWh ($0.05-0.07 per kWh). Now is the right time to ask yourself if your company’s energy strategy, from how and when you procure power and natural gas, to how you use it and manage risk, is keeping pace with today’s dynamic – and increasingly expensive – macro-environment. Put another way, in a world dominated by data centers, AI, and bitcoin, is your forging operation still buying and managing energy like an analog dinosaur?!

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FIA MAGAZINE | AUGUST 2025

ENERGY

Energy Auctions for the Win Typically, companies find that when they auction their energy their incumbent supplier beats its own “lowest price” (the one it offered in hopes of preventing you from taking your energy load to auction in the first place). This is a great outcome; but what’s even better is that often another supplier will come in even lower. It’s the beauty of the auction. Suppliers see the bids, too. They know that in order to win your business, they need to beat the competition, and that means continually lowering their price or getting outbid . Auctions keep everyone honest, and they heighten competition for your business, which drives down your energy cost. And they are run by energy professionals, so there is no extra work for you and your team. Whether you are looking to procure electricity or natural gas; a fixed-cost or variable product, or something in between; whether you a looking to hedge part or all of your load; whether you are looking for a term of 12 months, 24, 36, 48 or 60 months; it’s all auctionable .

And because the auction is a digital process run online (i.e., not a manual, paper-based process), it’s easy to bring these variations to market so you can see how the supplier community prices them. You gain pricing visibility across products and terms that is not available anywhere else in the market, enabling rational, data driven purchasing decisions . With energy prices and market volatility on the rise, forgers need every advantage they can get. Shift the balance of power your way with energy auctions. To learn more about energy auctions and how they can benefit your forging

operations, contact Nancy Gardner at ngardner@transparentedge.com or at 732-288-5126.

When the HEAT is on, so are we.

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Automation Solutions

FIA MAGAZINE | AUGUST 2025 9

ENERGY

COAL IS THE NEW BRIDGE FUEL By Bernard L. Weinstein

O nce again, the consensus of government and private weather forecasters is that this coming summer will witness above-average temperatures in most parts of the United States. Already, warnings have been sounded that America’s power grids will be under great stress—as has been the case for a number of years—with a strong probability of blackouts and brownouts in some parts of the country. For example, the North American Electric Reliability Corporation’s (NERC) summer reliability assessment published on May 18 cited the 15-state Midcontinent Independent System Operator (MISO) as the regional grid most likely to see a meltdown this summer. NERC’s warning proved to be prescient. On May 25, more than 100,000 customers in and around New Orleans lost power for most of the day when electricity demand exceeded supply, despite an emergency order from the Department of Energy several days earlier to keep a 1,560 megawatt coal plant in Michigan on-line that was slated for closure by the end of May. ERCOT, the Texas grid operator, has also warned of possible outages this summer due to potential low solar and wind energy availability during peak demand. The strains on America’s power grids are easy to explain. After remaining relatively flat for a decade, electricity demand is now projected to jump 50% over the next 10 years. Investments in server farms, artificial intelligence, crypto-mining, and a revival of manufacturing activity account for most of this growth. For example, a recent study by the Berkeley National Laboratory found that data centers consumed 4% of total U.S. electricity in 2023 but will account for 12% of power demand by 2028. At the same time, construction of new base-load power plants— natural gas, nuclear, and coal—has plummeted. Driven by federal, state, and local tax incentives, wind and solar have accounted for the lion’s share of new installed generation in recent years. The problem, of course, is that these power sources are intermittent, which is why New Orleans lost electricity in May and why the Iberian Peninsula suffered a blackout in April. Although several states—most notably Texas—have adopted programs to encourage new construction of natural gas plants, for the near term it’s critical to keep the nation’s remaining coal plants online. Since 2010, 300 “always on” coal-fired power plants have been closed, reducing its share of generation from 45% to 16% nationwide. Only about 200 remain on the regional grids today. The Trump administration has taken several steps to enhance power grid reliability and resiliency by keeping these coal plants on-line, including a series of executive orders signed by the President in early April. One of these orders allows a number of aging coal plants slated for closure to continue producing power. Not surprisingly, these actions have energized environmentalists who remain committed to shuttering the remaining coal fleet and banning the construction of any new fossil fuel power plants. But the renewables-or-nothing approach they favor is crashing into a new energy reality. Not only is power demand poised to surge but building and connecting wind and solar plants, as well as the infrastructure needed to integrate them into the grid, is proving increasingly costly and challenging. Coupled with higher

interest rates and supply chain challenges, local opposition to wind and solar farms, as well as new transmission lines, is having a significant impact on the speed and scale at which new generation is entering service. The era of tearing down existing, well-operating power plants before reliable replacement capacity is built and connected to the grid is over. The on-demand power plants already in service are more valuable than ever. While coal’s long-term future remains in question, its near-term importance is clear. Our existing fleet of coal plants can help us manage the transition to a more reliable and resilient energy future as we build the next generation of base load resources.

Bernard L. Weinstein is retired associate director of the Maguire Energy Institute at Southern Methodist University, professor emeritus of applied economics at the University of North Texas, and a fellow of Goodenough College, London. (Reprinted with the permission of RealClear Energy: https://www. realclearenergy.org/articles/2025/06/03/ coal_is_the_new_bridge_fuel_1114244. html)

FIA MAGAZINE | AUGUST 2025 10

EQUIPMENT & TECHNOLOGY

ROTARY HEARTH FURNACE FOR STEEL & ALLOY HEATING By Arturo Arechavaleta

In normal operation, this rotary furnace operates at between 1040°C (1900°F) and 1200°C (2190°F). Rotation is driven by a central bearing system mounted at the hearth substructure and operated by a pinion gear motor drive. An encoder is included, and hearth rotation is possible in both forward and reverse mode. There is a sand seal to ensure sealing between the furnace and the rotary hearth. Optimal billet heating is achieved within a single automatic temperature control zone, and is delivered by four high-velocity nozzle-mix burners, each of which is equipped with a lightweight alumina-mullite burner tile, and spark plug. The burners are positioned to heat tangentially over the load and the configuration results in high gas circulation inside the chamber, providing better control during the heating and soaking process, the required temperature uniformity, and better heat transfer to the product. Additionally, variable excess air control is applied at cycles with lower temperatures, enabling the best possible circulation and re-entrainment with a very high velocity mixing, ultimately achieving homogeneous and excellent temperature uniformity without the need for circulating fans inside the furnace. For enhanced process stability, furnace pressure is controlled via a transmitter that automatically measures internal pressure and sends a signal to the PLC that compares actual pressure against the required level. The PLC then transmits a signal to the actuator motors in the flues, to adjust the motorized dampers for automatic control of the furnace pressure. For superior performance, NUTEC Bickley fabricates a high-temperature resistance multi louver with silicon carbide shaft dampers for this purpose. The single vertical door and the furnace walls and roof are insulated with NUTEC’s proprietary ceramic fiber HTZ MacroModules. These form a 25cm (10in) thick extremely efficient lining that provides excellent insulation and is characterized by long life coupled with low maintenance requirements. Another result is superior operational performance, with NUTEC insulation allowing faster heating and cooling cycles. The rotary hearth itself is insulated with 15cm (6in) of hard refractory backed up by 15cm of insulating firebrick and a layer of insulation board. For all further information, please contact: Arturo Arechavaleta – VP Metal

A substantial forging and machining facility in the US has placed a contract with NUTEC Bickley for a rotary hearth furnace that will be used to heat billets of carbon steel and stainless steel alloys. The gas-fired furnace has been designed to deliver production rates of between 910kg (2000lb) and 1360kg (3000lb) per hour, depending on the size of the billets. Placed vertically on the hearth, the furnace can handle billets 7.6cm (3in) to 20cm (8in) in diameter and 12.7cm (5in) to 51cm (20in) in height. The heated materials are ultimately forged into a variety of high-specification components, such as fittings, flanges, plates, blanks and rings. Arturo Arechavaleta, NUTEC Bickley’s VP, Metal Furnaces, said: “Our customer’s products are used in high-pressure environments, such as oil & gas, petrochemical and advanced industrial manufacturing, and so there is a constant demand for excellence, accuracy and reliability. Here at NUTEC Bickley, our technical team has made significant advancements in rotary hearth technology, and all the latest concepts and improvements are brought together in this project.”

Furnaces, NUTEC Bickley Phone: +52 81 8254 0633 Email: arturoarechavaleta@nutec.com

FIA MAGAZINE | AUGUST 2025 11

EQUIPMENT & TECHNOLOGY

A SUPPLIER’S PERSPECTIVE FROM THE DIE UP By Bailey Taylor

I n the world of forging, the finished part often takes center stage, a testament to heat, force, and precision engineering. Yet behind every successful forging is a silent workhorse: the die. For those of us in tooling supply, this is where our attention lies. At EST Tool, our role is not to shape the metal directly, but to provide the instruments that do. This position affords us a unique view across a wide range of forging operations, materials, and strategies. While many FIA members are the manufacturers of forged components, our vantage point as a die supplier offers valuable insights into the foundational decisions that impact forging performance and production economics, particularly die material selection and surface treatment strategy. A Pattern of Preference: Finkl FX Xtra and Ellwood FORGEDIE Across the many forging operations we support, a clear material preference stands out: Finkl’s FX Xtra and Ellwood’s ExELL FORGEDIE. These steels have become go-to standards in hot work die applications, consistently delivering strong performance across a variety of forging styles. As nickel-chromium-molybdenum alloys, these materials offer an ideal balance of toughness, wear resistance, and thermal fatigue resistance, three properties critical to tool longevity in extreme conditions. Commonly hardened to 38–42 HRC, they are engineered to resist the mechanical and thermal stresses typical of forging while maintaining excellent through-hardening characteristics. This uniformity from surface to core ensures consistent performance across even the most demanding dies. The continued dominance of FX Xtra and FORGEDIE is not just a matter of familiarity, it’s grounded in years of practical field performance and the economic advantage of reliable tooling over long production runs. Exploring Alternatives: The Case for H13 and Beyond Despite the popularity of FX Xtra and FORGEDIE, they are not the only materials forging operations lean on. H13 tool steel, in particular, remains a strong performer in the right context. Known for its excellent thermal fatigue resistance, H13 is often selected for dies where heat checking is the limiting wear mechanism. We often see it hardened into the 50–60 HRC range, delivering superior wear resistance for applications where toughness is less critical. When forging geometry, production cycle, or part volume align with its strengths, H13 offers a viable and often more economical alternative. Other materials do see use, particularly in forging high temperature or highly abrasive alloys, but these tend to be specialized and require deeper consideration due to cost and complexity.

Surface Treatments and Weld Overlay: Added Performance, Added Complexity Once die material is selected, surface enhancement becomes a critical point of discussion. Nitriding, via gas, salt bath, or plasma, is one of the most common secondary treatments, introducing a hard, wear-resistant outer layer that improves lubricity, minimizes soldering, and boosts overall die longevity. A less frequently discussed but highly effective option is weld overlay, where specific areas of the die are surfaced with a high hardness filler material, often harder than the parent die steel. This allows targeted wear zones to be reinforced without compromising the toughness of the entire die block. When done correctly, weld overlay can dramatically extend the lifespan of vulnerable features such as parting lines, rib tips, or impact zones. However, both nitriding and weld overlays come with important trade-offs. From a manufacturing standpoint, any surface treatment or overlay complicates the machining process. Nitrided or welded surfaces are much more difficult to cut, often requiring specialized tooling and slower feeds and speeds. In the case of weld overlay, the die must typically be roughed, welded, then re-machined to final dimensions, a multi-stage process that adds time and cost. These challenges carry through to die maintenance and resinking as well. Machining treated surfaces is more difficult and often more expensive than working on untreated dies. In some cases, the cost and time required to rework a surface-treated die may outweigh its benefits for shorter production runs or lower-volume parts. The Economics of Tooling Decisions Each additional process step, whether it's a higher heat treatment range, nitriding, weld overlay, or other enhancements, adds cost to the die. Not only in terms of material or treatment fees, but also in tool life, machine time, and cutting tool consumption. For forging operations, the key question becomes: Does the increased cost to produce the tool result in enough added life to justify the investment? This is where data and experience play a pivotal role. In some high-volume, high-wear applications, it’s clear that enhanced tooling pays off quickly through reduced changeovers and lower downtime. In others, especially short runs or non-critical parts, basic dies without coatings or overlays may provide the best cost per-part value. The decision must be made with full consideration of the total die lifecycle, including maintenance, resinking potential, and machining difficulty. The best tooling strategy is rarely just about initial cost; it’s about total cost of ownership and the production context in which the tooling will operate.

FIA MAGAZINE | AUGUST 2025 12

EQUIPMENT & TECHNOLOGY

The Bigger Picture: Strategic Tooling in Context Die material and surface treatment decisions are part of a broader tooling strategy that should be customized for each operation. The most effective approach considers a range of interrelated factors: Part Geometry: Thin ribs, sharp transitions, and deep cavities can concentrate stress and accelerate localized wear. These features may require tougher steels, hard overlays, or coatings for protection. Forging Process & Equipment: A hammer delivers impact; a press applies steady force. Each imposes unique stress on the die and shifts the priority between toughness and wear resistance. Workpiece Material: Certain alloys are more abrasive or generate higher temperatures during forging. These materials can drive the need for premium base steels, coatings, or overlays. Production Volume: Longer production runs justify greater upfront investment in die life. For short runs, simpler tooling may be preferable to reduce turnaround time and cost. These considerations are best navigated through close collaboration between forger and toolmaker. The forger understands their process and equipment intimately; the supplier brings material science, machining strategy, and a cross-industry perspective. Conclusion: Partnering for Performance In forging, precision and performance don’t start at the press, they start at the die. Materials like FX Xtra and FORGEDIE have earned their reputation, but the continued use of alternatives, strategic nitriding, and weld overlays demonstrate that innovation in tooling is alive and well.

At EST Tool, we believe every die should be purpose-built, not just to meet spec, but to align with the economic and production realities of the forger. Whether that means specifying a tried and-true base material, incorporating a weld overlay in high wear zones, or skipping coatings altogether, the decision is never one-size-fits-all. In a process measured in tons of force and fractions of a second, even the smallest tooling decision can carry enormous weight. As suppliers and partners in this industry, our job is to help make those decisions smarter, and to ensure that every die is built not just to perform, but to last.

Bailey Taylor Sales Associate

EST Tool & Machine, Inc. Email: Bailey@esttool.com Phone: 606-758-4626

2025 Forging Lightweight Alloys Conference & Plant Tour

September 15-17, 2025

The Forging Lightweight Alloys Conference & Plant Tour will take place September 15 17 at the Hilton Long Beach in Long Beach, California. The conference will cover topics including lightweight materials, OEM needs, advancements in technology, equipment for lightweight forging, post-forging processes and more.

Hilton Long Beach 701 W. Ocean Blvd. Long Beach, CA 90831

Visit www.forging.org/events for more information

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A s the forging industry continues to evolve under the pressures of advanced applications, economic fluctuations, and a tightening labor market, material and tooling suppliers are at the forefront of innovation. In this month’s cover story, FIA explores the latest trends shaping forging materials and tooling technologies—from the rise of ultra-clean alloys to quick-change die systems and evolving customer demands. THE LATEST TRENDS IN MATERIALS AND TOOLING TECHNOLOGY By FIA Staff

The Importance of Early Material Selection Material selection has become a strategic decision that can significantly affect downstream success. Oettli cautioned that many quality certifications can be vague or incomplete when it comes to cleanliness or soundness. “Customers should be careful when interpreting quality statements on certifications,” he said. “Claims about bearing or aircraft quality must be verified to ensure fitness for demanding applications.” McIntosh added that assumptions based solely on generic specs can lead to issues later in the process: “It’s important to understand and communicate end-use requirements so that appropriate processing and inspection can be selected.”

Forging Materials: A Push Toward Precision and Performance High-Performance Alloys on the Rise Over the past 12 to 18 months, the industry has seen a significant uptick in demand for high-performance ultra-clean specialty metals, especially those produced via Vacuum Induction Melting (VIM) and Vacuum Arc Remelting (VAR) processes. These materials, essential for aerospace and defense applications, are driving mill expansions and multi-sourcing efforts. “There is continued growth in high performance ultra-clean specialty metals,” said Graham McIntosh, EVP & CTO at Universal Stainless. “This is particularly evident in the aerospace markets and is leading to both mill capacity expansions and increased multi-sourcing opportunities.” Matt Oettli, Director of Product Management at Metallus, reinforced this trend: “We’re seeing higher demand for vacuum remelt grades specific to defense applications, reflecting overall growth in that sector.” However, he added that the fundamental mix of product types remains largely unchanged—though quoting activity has increased for items previously absent from catalogs, likely due to reshoring or re-sourcing initiatives.

Collaboration and Material Optimization As cost and performance pressures mount, collaboration between forgers and material suppliers is more important than ever. Oettli stressed the importance of early engagement: “There’s still significant opportunity to engineer specific grades of steel to meet requirements in strength, toughness, and corrosion resistance. Lower alloys can sometimes replace expensive stainless grades. That kind of optimization happens through collaboration.” He also noted that more dialogue—not just RFQs—could unlock better solutions: “OEMs and forgers often don’t tap into the institutional knowledge we have. Deeper conversations about material behavior and properties can drive better outcomes for demanding applications like gearing, bearing, and shafting.” Supply Chain Stability—But With Caveats The materials supply chain is relatively stable, according to Oettli. “Lead times are modest and pricing for common grades is stable. Domestic capacity is adequate overall,” he said. However, he warned of broader structural challenges: “Strategic investments in people and production are difficult in the face of variable demand and government policy shifts.” He also highlighted the long-term threat of global overcapacity: “The biggest threat to domestic forging isn’t material availability—it’s finished product from overseas. Countries like India and China are significantly expanding forging capabilities.”

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Photo Courtesy of Gemini Group.

Photo courtesy of EST Tool.

Forging Tooling: Smarter, Faster, and More Durable Customer Demands Drive Innovation Tooling suppliers report increased pressure to deliver longer-lasting, more precise tools at faster turnaround times. Stephanie Speck of Gemini Group emphasized tooling design as key to performance, while Beau Parker of EST Tool pointed out the rise in tighter tolerances, high temperature durability, and demand for engineering support upfront. When asked about how customar demand has changed recently, Speck stated “We’ve seen more customers outsource tooling design rather than keeping it inhouse due to lack of resources.” “Customers now expect tooling to hold up longer and be ready faster,” Parker said. “This includes working with more complex alloys like Inconel and titanium.” Quick-Change Tooling and Digitalization Quick-change die systems and replaceable inserts are gaining popularity for their ability to reduce downtime and adapt to short runs. “Die design and using insert or quick change tooling will bring cost down and production up,” according to Speck. Parker’s team at EST Tool also supports customers through surface treatments, optimized tool steel selection, and digital planning. EST Tool’s integration of the ZOLLER presetter and Tool Management System has allowed them to improve setup speed, tool accuracy, and quality traceability. “We’ve cut down setup time and increased repeatability across jobs,” said Parker.

Addressing Lead Times and Labor Gaps To meet demand, Parker shared that EST Tool is investing in new ERP software, advanced scheduling, and reserving capacity for key customers. “Expedited requests have become the norm in 2025,” he said. In response to the industry-wide talent gap, the company is documenting processes and leaning into digital tools to preserve expertise for the next generation. Supporting Performance with Surface Treatments Advanced tool steels such as Dievar and ESR-grade H13 are now more common in forging. EST Tool also applies vacuum heat treatments, nitriding, PVD coatings (TiN, AlCrN), and even cryogenics to reduce wear and extend tool life—particularly in high Both Parker and Speck highlighted the importance of working closely with customers. EST Tool recently supported a new client by designing custom trimmer dies that performed successfully from the first run. “We tailored the design to their part geometry, press specs, and production flow—no rework needed,” Parker said. Looking Ahead: The Next Five Years Material and tooling experts agree that the future of forging will be defined by: • Smarter Tooling: Automation-ready designs, simulation-driven setups, and modular systems • Strategic Sourcing: Multi-sourcing strategies and domestic supplier relationships • Digital Integration: Simulation, CAD/CAM linkages, and inventory-driven planning • Workforce Transition: Tools and processes that support knowledge transfer and ease training Precision, Planning, and Partnerships Whether dealing with cutting-edge alloys or complex die geometries, the future of forging relies on close collaboration and technical transparency. “More collaboration across the supply chain—from material properties to downstream tooling—can dramatically improve outcomes,” said Oettli. “It’s not just about quoting specs. It’s about sharing knowledge early in the process.” McIntosh agreed: “Challenge single-sourcing mandates and support options that improve flexibility.” Thank you to Beau Parker (EST Tool); Matt Oettli (Metallus); Graham McIntosh (Universal Stainless); and Stephanie Speck (Gemini Group) for their contributions to this article. volume or abrasive applications. Collaboration Leads to Success

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F orging die wear isn’t just expected, it’s inevitable. How you deal with it makes all the difference in uptime, part quality, and your bottom line. At Gemini Precision Machining, Inc., we’ve spent decades on shop floors, and we’ve learned this: there’s no one-size fits-all answer to tooling wear. What you need is a smart, tailored strategy that considers the type of wear, the volume of parts, and your die geometry. In this article, we’ll break down the common types of die wear and failure and provide practical tooling and refurbishment strategies that can extend die life and increase efficiency. FORGING DIE WEAR: UNDERSTANDING FAILURES, EXTENDING DIE LIFE By Dan Ullrich and David Mills

die was addressed by rethinking the insert design. A two-piece insert was developed where the floor and plug were one component, and the wall was a second insert. This placed the crack-prone area at the boundary solving the problem with smart design. • When the walls of a die are too thin , the dies can crack. As a rule of thumb, the die wall thickness should be 1.5X the depth of the cavity or more. For round parts with deep die cavities, a shrink-fitted insert may be the solution. A crack can only form if the die is in tension. If you apply compressive stress to the OD of the insert, these cracks can’t initiate.

Understanding Die Wear 1. Thermal Fatigue Thermal fatigue is a classic case of the environment turning against you. During forging, the die heats up rapidly as it's struck repeatedly by red-hot billets. Then it’s suddenly cooled by die lubricant, water spray, or air. This extreme and repeated cycle of expansion and contraction leads to surface cracking. Over time, the die surface begins to resemble alligator skin. Although thermal fatigue is expected, certain die strategies such as using tougher materials or maintaining a consistent die temperature can slow the progression. 2. Erosion Erosion is normal wear; material is gradually being removed from the die face due to friction. Erosion leaves directional lines aligned with the flow of material over the die. These patterns will appear in areas of high material flow, such as plugs and flash land. 3. Cracking Cracks in dies can be a bigger problem and are often more preventable than people think. Cracking has multiple causes: • Trapped gas in the die cavity can build extreme internal pressure, causing cracks. The fix? Venting. Designing in strategic escape paths or using die inserts that double as vents is highly effective. • Stress risers such as tight radii, tool marks, weld defects, or even embossed lettering create concentrated points of stress where cracks tend to initiate. Smoothing these areas and avoiding sharp transitions helps. • Mechanical overload is another culprit, where forging loads exceed the material’s strength. In one real-world example, a crack in the bottom of a

Tooling Approaches That Extend Die Life Insert Tooling

Insert tooling is a modular approach where only the critical working surface of the die, the area that wears the fastest, is removable and replaceable. Inserts are machined to tight tolerances and dropped into a reusable holder block. Inserts can be swapped out when

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worn or damaged without replacing the entire die block. Best for: • High volume runs: If your tooling sees more than 30,000 hits, inserts reduce downtime, simplify replacement, and cut costs for coating and heat treating. • Shallow impressions: Less than 1.25” deep. These are prime candidates for insert tooling. You can use harder materials (46–50 Rc), and refurbishing inserts is quicker and cheaper than resinking full blocks. • Parts requiring benders: In C- or U-shaped forgings, using inserts for finishers/blockers means you don’t have to resink the bender each time. Benders last much longer anyway, so leaving them in the block makes sense. Flood Welding For deeper impressions or lower-volume jobs, flood welding remains a solid choice. By scarfing out worn cavities and rebuilding with lower-alloy filler materials as a base and higher-alloy near the flashland to reduce wear. Dies can be refurbished efficiently but not indefinitely. After three weld-resink cycles in the same area, it’s best to cut down the die face by ½”, resink as new, and protect against carbon depletion. Best for: • Lower alloy dies (FX and equivalents) Although you can weld H13 dies you need to be more strict on the welding procedure as you may see more cracking than you would on the lower alloys during the welding process. Benefits: • Shorter lead times as you are not waiting for materials, most weld materials are in stock. • More controlled hardness. By using multiple materials, you can use softer material where it tends to crack and harder material on the flash land area where you would see more wear.

Considerations: • Layer welding is typically done using robotic welding but can be done manually. • Spot welding is fixing the cracked or worn areas only. • Flood welding is scarfing out the entire cavity and filling it completely with weld. • It is important to choose the correct weld materials . It is important to use proper welding procedures to avoid making the situation worse.

Final Thought: It’s All About the Strategy There’s no universal “right” answer in die wear management only the best decision for your volume, geometry, and failure mode. The smartest companies we work with know tooling is not just an expense, it's a performance lever. By understanding the type of wear you're facing and applying the right mix of inserts, venting, stress relief, and refurbishment techniques you can gain control over die life, part quality, and production efficiency. Want help figuring out the best strategy for your forge tooling? We’re here for that. Dave Mills Senior Account Manager Gemini Precision Machining Email: dmills@geminigroup.net Phone: 248-804-4929

Dan Ullrich Senior Tooling Engineer Gemini Precision Machining Email: dullrich@geminigroup.net

Dave Mills

• Lower machining hours because you’re only machining the cavity.

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