August 2026 Volume 8

OFFICIAL PUBLICATION OF THE FORGING INDUSTRY ASSOCIATION | FORGING.ORG | AUG 2026

The Material Advantage

How Forgers are Navigating Cost, Capacity and Critical Supply Risk Page 36

Beyond the Die Steel: The Materials Behind Modern Forge Tooling Page 34 Designing for Die Life Page 21

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LETTER FROM THE EDITOR

E very successful forging begins long before it hits the hammer or press. It begins with the selection of the right material, the design and manufacture of the tooling, the condition of the equipment and the knowledge of

Technology is creating new opportunities as well. Artificial intelligence may help manufacturers identify process drift, improve maintenance decisions, optimize energy use and preserve valuable operational knowledge. However, as this issue explains, successful applications begin with a clearly defined plant problem—not with technology for technology’s sake. The goal should always be a safer, more consistent and more productive operation. None of these decisions takes place in isolation. Material, tooling and equipment supply chains are increasingly affected by tariffs, trade policy, geopolitical developments and government efforts to strengthen domestic manufacturing. Understanding where materials and machinery originate—and where vulnerabilities exist—has become a necessary part of operational and strategic planning. Although these articles cover different subjects, they share a common message: Long-term competitiveness depends on preparation, trusted partnerships and a willingness to continually evaluate how work is being done. As I officially move into my new role as FIA's President, my priority is to ensure that FIA continues helping members navigate these challenges. Through technical education, benchmarking, advocacy, industry events and opportunities to learn directly from one another, we remain committed to providing practical value that strengthens North American forging companies. I hope the ideas in this issue encourage conversations within your own facilities. Where are your most significant material or tooling risks? Which supplier relationships need to be strengthened? What knowledge needs to be captured? Where could better planning, data or technology improve performance? Thank you to the FIA members, committees, technical experts and industry partners who contributed their knowledge to this edition. Your willingness to share real experiences and practical solutions is what makes FIA Magazine a valuable resource for the entire forging community. Best regards,

the people responsible for the process. It also depends on decisions involving maintenance, suppliers, technology, inventory and increasingly complex global supply chains. That is why materials and tooling remain such an important focus for the forging industry. They influence quality, productivity, energy use, equipment uptime, delivery performance and ultimately a company’s ability to compete. This issue of FIA Magazine looks beyond the finished forging to examine many of the decisions and resources that make reliable production possible. Our contributors explore how the environment surrounding tooling production continues to evolve. Although familiar die steels remain essential, advances in cutting tools, carbide grades, coatings and machining strategies are changing how tooling is manufactured. At the same time, the cost and availability of carbide and other critical inputs are encouraging companies to reconsider sourcing strategies, inventories, recycling programs and supplier relationships. Those pressures reinforce an important lesson: Resilience is rarely created through one major investment. It is built through hundreds of disciplined decisions made throughout an operation. That includes taking the time to thoroughly inspect and understand equipment before beginning an upgrade or retrofit. Careful planning can identify worn components, long lead-time parts and potential problems before a scheduled project turns into extended, unplanned downtime. It also means asking better questions before purchasing equipment. Forging equipment represents a long-term commitment, and the right supplier should provide more than a machine. They should understand the realities of the forging environment and be prepared to support safety, integration, training, maintenance, troubleshooting and future improvements throughout the equipment’s service life.

Angela Gibian, CAE President Forging Industry Association

Editorial Staff

CHAIRPERSON Paul A. Spitz Vice President - Sales & Marketing | Unit Drop Forge Co. Inc. VICE CHAIRPERSON Jeff Krueger Exec. Dir. of Corp. Sales | Scot Forge Co. Robert R. Bolin President | GLAMA USA Inc. Mark Derry VP Operations | Portland Forge Board of Directors

Rick Egbert VP & CFO | Carbo Forge, Inc. David Alexander Director of Business Planning | DAUCH Corporation Bret Halley COO | Valley Forge & Bolt Mfg. Co. James D. Kane VP of Commercial Sales | Ellwood Quality Steels Co.

Louis Philippe Lapierre COO | Finkl Steel Frank Sikon Director of Procurement Operations | Howmet Aerospace Luke Spinelli Executive VP - COO | Aluminum Precision Products, Inc.

PUBLISHER & EDITOR Angela Gibian President | Forging Industry Association angela@forging.org ASSOCIATE EDITOR Amanda Dureiko Executive Director (FIERF) | Forging Industry Association amanda@forging.org DESIGN Lorean Crowder Sr. Graphic Design & Publication Specialist | Forging Industry Association lorean@forging.org

FIA MAGAZINE | AUGUST 2026 3

CONTENTS

AUGUST 2026 | VOLUME 8

INDUSTRY NEWS 51 Remembering Dan Ulven 52 Forged Solutions Group Completes Acquisition of Custom Alloy 53 DOW Launches BuildFreedom. US, Announces $10M Skilled Trades Investment With Mike Rowe and Forge the Next-Generation Industrial Workforce 53 Federal Assistance for Defense Related Forging Product Supply Issues 54 Forging Industry Association Announces Leadership Changes 55 H.I.G. Capital Completes Acquisition of Premier Forge Group 56 Faces of Forging 58 Welcome New Members 58 Forging Day 2026 62 Forging the Future Starts Early 64 Donor Spotlight: AMl & Gemini FORGING RESEARCH 66 Accuride Works To Engineer the Grain Structure of 6XXX Series Aluminum Alloys Using Process and Microstructure Modeling MEMBERS SPEAK 68 A View from the Industrial Middle AD INDEX 71 August Advertiser Index 61 FIA Upcoming Events FOUNDATION NEWS

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SAFETY 26 FIA 2026 Safety Conference Focuses on High-Consequence Manufacturing 27 Musculoskeletal Issues Facing the Forging Industry 30 OSHA Reveals Plans for Heat Illness and Emergency Response Rules AUTOMATION 31 Beyond the Buzz: A Practical Path to AI on the Forging Floor MATERIALS 34 Beyond the Die Steel 36 The Material Advantage OPERATIONS & MANAGEMENT 40 The Basics of Employee Pay 42 Preparing Replacements and Navigating Transitions 44 Cyber Risk, Business Interruption, and Insurability 46 2026 Forging Performance Looking Up 48 Quick Guide to Microsoft 365 Security

LETTER FROM THE EDITOR 3 Letter from the Editor WASHINGTON UPDATE 6 From Material to Machine ENERGY 8 Myth Buster: Why ‘Shoulder Season’ Isn’t Best for Buying Energy 10 Energy Cost Savings Opportunities in the Forging Industry EQUIPMENT & TECHNOLOGY 14 The Evolution of Power Supply Technology for Induction Forging Systems 17 10 Questions Forgers Should Ask Their Equipment Suppliers 21 Designing for Die Life MAINTENANCE 24 How to Minimize Downtime During Upgrades or Retrofits

OFFICIAL PUBLICATION OF THE FORGING INDUSTRY ASSOCIATION | FORGING.ORG | AUG 2026

The Material Advantage

How Forgers are Navigating Cost, Capacity and Critical Supply Risk Page 36

Beyond the Die Steel The Materials Behind Modern Forge Tooling Page 34 Designing for Die Life Page 21 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 © 2026 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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WASHINGTON UPDATE

FROM MATERIAL TO MACHINE The Washington Supply Chain By Omar S. Nashashibi

I n the past decade, my conversations with manufacturers about materials, machinery, and tooling have evolved. Price and availability are always considerations, but the primary discussion often centered on technical capabilities, tolerances, and metallurgical composition. Outside of an antidumping or countervailing duty case, the U.S. government was rarely a meaningful factor in manufacturing supply chains. Today, every sourcing decision must account for Washington and the actions of governments across the globe. Those earlier conversations evolved into a focus in the first Trump administration on whether he would impose tariffs. By 2019, manufacturers would ask about tariff exclusions and exemptions and if these tariffs were just a temporary negotiating tactic. In 2026, no one asks me if they are temporary and everyone recognizes that the current largest variable in their procurement is Washington. The U.S. is imposing tariffs on steel, aluminum, and copper under a Section 232 tariff action. Canada in July 2025 began a tariff rate quota regime along with up to a 50 percent rate on steel imports. Facing a barrage of imports from China, the European Union lowered its threshold for its own steel tariff rate quota system. Capitals worldwide are prioritizing critical minerals, and in some cases, placing export restrictions on essential inputs with few alternate sources. The Biden administration jumpstarted a global semiconductor and green technologies race for tooling by passing major legislation subsidizing U.S. industry, which led other governments to create or expand their own subsidies. The second Trump administration, in an effort to increase domestic demand, made permanent multiple tax incentives for purchasing equipment and conducting R&D activities. Government inaction can also factor into material and supply decision making. The tooling industry in the U.S. today is a fragment of what once existed in the 1980s. Heavy equipment is often assembled domestically; however, U.S.-owned and operated machine builders are increasingly difficult to find. The interventions by governments these past few years will likely increase as politicians race one another across a range of priorities related to national and economic security with machinery and tooling being front and center. This leads to the U.S. Department of Commerce investigation into industrial machinery and robotics, which may result in tariffs under the Section 232 national security law. The scope covers CNC machining centers, industrial stamping and pressing machines, automatic tool changers, jigs and fixtures, and machine tools for cutting, welding, and handling workpieces, along with application-specific specialty metalworking equipment used to treat, form, or cut metal, such as autoclaves and industrial ovens. We have met with the White House, the Commerce Department, and the office of the U.S. Trade Representative, and their commitment to increasing the domestic manufacturing of machine tools is quite evident. Washington is expecting companies to invest billions in heavy equipment facilities in the U.S.,

accompanied, of course, with the promise of tariffs to protect those investments. The timeline for President Trump to act on industrial machinery tariffs could materialize in the coming months as active talks with stakeholders continue in the nation’s capital. While the pending 232 investigation may bring additional tariffs on industrial machinery later this year, those purchasing tooling and select equipment from overseas already face tariffs under an existing 232 regime with a second pending. In April 2026 and again in June, the Commerce Department realigned the existing Section 232 steel, aluminum, and copper tariff program to create separate categories with a temporary reduced 15 percent rate for certain machines until January 1, 2028, when the rate increases to 25 percent. The change was both an acknowledgement and a message from the administration that even the slightest increase in cost of machinery that can range into the millions of dollars has a direct impact on their goal of growing domestic manufacturing. The most recent effort to replace the President’s global tariffs is the Section 301 Forced Labor investigation into sixty economies, including the EU, Japan, China, India, Canada, and Mexico. The Office of the USTR in June 2026 proposed a 10 percent or 12.5 percent tariff on imports from these countries and in a separate Section 232 action covering manufacturing excess capacity, specifically cited machine tools and machinery imports from countries such as Germany, Switzerland, and Japan. The Trump administration is taking a whole-of-government approach to materials, machinery and tooling. Although the January 2026 industry survey showed that 50 percent of forging respondents said that tariffs on raw materials had increased their costs, it is often these same tariffs that cover forgings themselves. This should remind all that, support them or not, tariffs will remain a factor. With a 59 percent capacity utilization rate, the industry has room to grow, which is exactly what the Pentagon wants to hear. They too are holding meetings in Washington and around the country specifically focused on machinery and tooling capabilities. Defense officials are convening stakeholders to identify and catalogue U.S. suppliers capable of supporting the defense industrial base. On Capitol Hill, lawmakers are increasingly asking questions over the origins of equipment and tooling in manufacturing plants across their Congressional Districts. A focus that began with China is expanding to examine the reliance on allies for tooling, machinery, and some materials. This is not a singular one-off action or a fleeting interest of politicians. Voters do not cast their ballots based on tooling and heavy equipment. Candidates for office do not stump on the campaign trail speaking about machine tools. Yet the focus has reached the highest levels of the U.S. Government. The President’s focus on materials such as steel and aluminum is well known. However, he has now instructed his cabinet to expand their tariff efforts to the equipment making the forgings and other components that the Trump administration seeks to protect.

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WASHINGTON UPDATE

Having insight into your supply chains from material to machine is critical for any manufacturing organization in 2026. Failure to factor in the actions of Washington and other governments could prove costly.

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.

FIA MAGAZINE | AUGUST 2026 7

ENERGY

MYTH BUSTER: WHY ‘SHOULDER SEASON’ ISN’T BEST FOR BUYING ENERGY By Nancy Gardner

S easoned energy buyers understand that the timing of an energy purchase is one of the most critical factors in reducing costs and achieving budget stability. For decades, there has been a misconception that the best time to procure electricity and natural gas is during the ‘shoulder season’ – either in the spring or autumn when energy demand is lower, and prices tend to soften. While a quick glance at the forward NYMEX natural gas curve shows prices are, in fact, lowest during these times of the year, as highlighted in the grey bars below, there’s more to the story.

When is the Best Time to Procure Energy? Any time of the year can present favorable opportunities to manage energy costs, structure purchases, and adjust your purchasing strategy. Typically, when forward prices are elevated relative to historical benchmarks, an energy buyer would be better served taking on more risk by assuming partial exposure to market indices. As we highlighted at the start of the year, situational awareness and flexibility are crucial elements of a long-term procurement strategy. More important than ‘what time of year should I buy’ is ‘what time of year do I need to be hedged?’ Over the past several years, the answer to that question has become much clearer. While both summer and winter tend to yield higher prices and greater volatility, it is winter that has become the most dangerous time of year to be exposed to market-based energy rates. Here is a look at the top 10 highest price days of electricity over the past 365 days in each of five markets — 50 data points in total (prices in $ per MWh): Highlighted in blue are days that occurred during the winter months. While there are a few summer days mixed in, only 9 of the 50 highest price days occurred outside of winter. While prices

Why the ‘Shoulder Season’ Buying Myth? Real-time and spot energy prices are lowest during the non-summer/non-winter months; however, energy purchases are typically built around an annual or multi-year term. This requires an evaluation of the forward price strips. When a supplier quotes a fixed price, it is a volume-weighted

average of monthly energy consumption multiplied by the forward price for each future month. Just because spot prices are lowest during shoulder months does not mean that spring and fall are the best times to buy energy. Here is a look at forward electricity prices in Texas on two different dates. On March 2, 2026, a buyer looking to hedge 2027 electric costs would have done so at $53.81 per MWh. Four months later, during one of the hottest weeks of the year, that same strip of power was selling for $49.89 – more than 7% lower than the price earlier in the spring:

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If you are interested in taking action to protect your energy budget against future price risk — or if you want help understanding the forces driving energy markets today — contact Nancy Gardner at ngardner@transparentedge.com. ENERGY

were certainly elevated ahead of the 4th of July holiday, the impact on pricing paled in comparison to the exceedingly expensive electricity prices that occurred over the past winter. What Does This Mean for My Business? Fortunately, the winter of 2026/2027 is still five months away. We strongly recommend that any power or natural gas user with exposure to winter prices begin working immediately to lock in rates for the upcoming winter. If you have already secured a fixed rate beginning in December 2026, it would be prudent to look further ahead to the winters of 2027/2028, 2028/2029 and 2029/2030. Timing is important to capture future energy prices as dips occur in the market. It doesn’t matter which time of year you sign an energy contract — what matters is that you are protected during the periods when prices are most likely to move dramatically higher.

FIA MAGAZINE | AUGUST 2026 9

ENERGY

ENERGY COST SAVINGS OPPORTUNITIES IN THE FORGING INDUSTRY Why Energy Efficiency Has Become a Competitiveness Issue for Forge Shops By Angela Gibian, CAE

E nergy has always been one of the forging industry’s most important cost drivers. But in 2026, it is no longer just a utility bill to manage in the background. For forging producers, energy now sits at the intersection of cost control, production efficiency, capital planning, customer expectations and long-term competitiveness. Forge shops operate in some of the most energy-intensive corners of manufacturing. Gas-fired furnaces, induction heaters, heat treat lines, compressors, hydraulic systems, pumps, fans, cranes and dust collection systems all draw significant energy. In high Government Funding and Support for Forging Energy Projects For forging companies considering energy-saving projects in 2026 and beyond, several federal programs can help reduce the cost of assessments, planning and implementation. While eligibility varies by company size, project type, location and funding availability, these resources are worth reviewing before a plant funds an energy project entirely on its own. DOE Industrial Training and Assessment Centers The U.S. Department of Energy’s Industrial Training and Assessment Centers, commonly known as ITACs, provide in-depth facility assessments for small and medium-sized manufacturers. These assessments are typically conducted by university-based engineering teams and include a site visit, engineering measurements, process analysis, and a confidential report with recommendations, estimated costs, performance impacts and payback timelines. This can be especially useful for forge shops that need a structured starting point. ITAC assessments may identify opportunities in process heating, compressed air, motors, pumps, fans, waste heat recovery, production efficiency and other plant systems. ITAC Implementation Grants The ITAC Implementation Grants program can help eligible small and medium-sized manufacturers implement recommendations from qualified energy assessments. DOE states that grants of up to $300,000 per qualified recommendation are available for energy efficiency projects.

temperature operations, even small inefficiencies can become expensive quickly. A furnace door left open too long, a burner running out of tune, a compressor feeding unrepaired leaks, or a motor running continuously between production cycles may look minor in the moment, but over the course of a year those losses can add up to real money. The timing for this conversation is important. In 2024, the U.S. Department of Energy announced up to $6 billion for 33 industrial demonstration projects focused on energy-intensive sectors such as iron and steel, aluminum, cement, chemicals, For forging producers, this may be relevant to projects such as compressed air upgrades, furnace controls, variable frequency drives, process heating improvements, waste heat recovery, energy monitoring systems, and other measures identified through a qualifying assessment. Companies should confirm eligibility and current funding availability before applying. DOE Better Plants Program DOE’s Better Plants program is a voluntary partnership designed to help industrial organizations improve competitiveness by reducing energy, water and waste costs. Participating manufacturers typically set long-term energy intensity reduction goals and receive access to technical support, national lab expertise, in-plant trainings, webinars, software tools and recognition. This may be a good fit for forging companies that want a more formal energy management structure across one or multiple facilities. The program can help companies move beyond one-off projects and build a repeatable process for measuring, managing and improving energy performance. DOE 50001 Ready DOE’s 50001 Ready program provides a no-cost pathway for companies to implement an energy management system aligned with ISO 50001, without requiring third-party certification. The online Navigator tool walks facilities through the major elements of an energy management system, including energy planning, performance tracking, operational controls, management review and continuous improvement. For forge shops, 50001 Ready can be useful even if formal

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ENERGY

glass, food and beverage, and process heat. The message to manufacturers is clear: industrial energy use, especially high temperature process heat, has become a national competitiveness issue. 1 For forging companies, the opportunity is practical. Energy savings do not always require a complete plant transformation or a leap into unproven technology. Many of the most realistic savings come from better control of existing equipment, improved furnace practices, reduced idle time, combustion tuning, maintenance discipline, waste heat recovery, compressed air improvements, motor controls and formal energy management. In other words, the first step is not necessarily to buy new equipment. The first step is to understand where the energy is going and where it is being wasted. Start with the Furnace For most forge shops, the biggest opportunity begins with process heating. Furnaces and heating systems influence not only energy costs, but also throughput, scale loss, part quality, maintenance needs and production flow. A furnace that is poorly tuned or poorly scheduled does not simply waste natural gas or electricity. It can slow production, create inconsistent heating, increase rejects and reduce the efficiency of downstream operations. This is why forge shops should treat furnaces as production assets, not just heat sources. The same discipline applied to presses, hammers and machining centers should also be applied to furnace certification is not the goal. It provides a practical framework for assigning ownership, tracking energy intensity, identifying significant energy users and keeping savings from disappearing over time. DOE Onsite Energy Technical Assistance Partnerships DOE’s Onsite Energy Technical Assistance Partnerships provide technical assistance to industrial facilities and other large energy users evaluating onsite energy options. These may include combined heat and power, battery storage, district energy, fuel cells, geothermal, industrial heat pumps, renewable fuels and other onsite technologies. This resource may be most relevant for larger forging operations or multi-site manufacturers evaluating resilience, energy reliability, peak demand reduction, waste heat utilization or onsite generation. NIST Manufacturing Extension Partnership The Manufacturing Extension Partnership, administered by the National Institute of Standards and Technology, supports small and medium-sized manufacturers through state-designated MEP Centers across the United States and Puerto Rico. MEP Centers provide local support on operational improvement, competitiveness, productivity, supply chain resilience, technology adoption and related manufacturing needs. For forging companies, the local MEP Center may be a useful first call when evaluating energy projects, grants, operational improvements or connections to other state and federal resources.

performance. That includes measuring utilization, tracking fuel use, reviewing downtime, monitoring temperature consistency and understanding how operating practices vary by shift. One of the most common sources of waste is idle heat. Furnaces are often held at temperature while waiting for material, tooling, labor, handling equipment or the next production run. In some cases, this is unavoidable. In many cases, it is a scheduling and communication problem. Better coordination between furnace operators, press crews, maintenance and production planning can reduce the amount of time furnaces are hot but not productively heating material. Loading practices also matter. How often are doors opened? How long do they stay open? Are billets staged properly before loading? Are operators following consistent practices across shifts? Every unnecessary door opening brings in cold air and releases heat that must be replaced. In high-temperature environments, those habits are not trivial. A useful example comes from Gränges, a global aluminum manufacturer. The company has studied furnace loading sequence, burner parameters, temperature, pressure, operator practices, door openings, sensors and artificial intelligence as part of its energy savings work in aluminum casting and melting. While aluminum melting is not forging, the lesson transfers well: in heat-intensive manufacturing, operator practices and process control can have a meaningful effect on energy use. 2 Federal Tax Incentives Companies should also review federal tax incentives with their tax advisors. For example, the Section 179D Energy Efficient Commercial Buildings Deduction may apply to certain qualifying building energy efficiency improvements, including building envelope, HVAC, hot water and lighting systems. Other incentives, such as the Section 45X Advanced Manufacturing Production Credit, are more specialized and apply only to manufacturers producing certain eligible clean energy components or critical minerals. Because tax rules, eligibility and deadlines can change, companies should confirm current requirements before making project decisions. Practical First Step Before starting a major energy project, forge shops should gather 12 to 24 months of utility data, identify their largest energy users, document known problem areas, and contact their utility provider, local MEP Center, DOE ITAC, or an energy assessment provider. A strong assessment can turn plant-floor observations into a prioritized list of projects with estimated savings, payback periods and potential funding pathways. For more information on these opportunities and how FIA can help support you and your business, please contact Spencer Bell, FIA Director of Government Relations at spencer@forging.org.

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ENERGY

Tune Combustion and Reduce Excess Air For gas-fired forge and heat treat furnaces, burner tuning is one of the most practical and often overlooked opportunities. An incorrect air-to-fuel ratio can waste fuel, reduce temperature uniformity and contribute to scale formation. Excess air may appear harmless because it supports combustion, but heating extra air to forging temperatures consumes energy that does not add value to the part. DOE process-heating guidance identifies burner air-to-fuel ratio control, furnace pressure control, reduced air infiltration, improved insulation, preheated combustion air and waste heat recovery as major opportunities in industrial process heating. 3 For a forge shop, this translates into a practical checklist: verify burner setup, inspect oxygen-trim controls where applicable, repair door seals, check dampers, maintain pressure balance and make sure operators understand the cost of running outside desired furnace conditions. This is not just a sustainability measure. A properly tuned furnace can support better temperature control, more consistent production, less rework and lower fuel consumption. Plants should consider regular combustion audits, especially on older furnaces or equipment that has been modified over time. Capture Waste Heat Before Buying More Energy Waste heat recovery is another major opportunity in heat-intensive manufacturing. Fuel-fired furnaces, ovens, boilers and other thermal systems can send large quantities of usable heat up the stack. Depending on the process, recovered heat may be used to preheat combustion air, preheat incoming stock, heat wash water, support space heating, or serve another nearby process. DOE identifies waste heat recovery, load preheating using flue gases, preheated combustion air and using waste heat for external processes as process-heating improvement opportunities. 3 In a forge shop, the feasibility depends on exhaust temperature, cleanliness of the exhaust stream, operating schedule, available space and whether there is a consistent use for the recovered heat. A large-scale example comes from Cleveland-Cliffs. The company reports that at some of its integrated steel operations it recovers energy from by-product process gases to generate electricity. In 2024, Cleveland-Cliffs reported that on-site generation supplied approximately 75% of electricity needs at its Burns Harbor mill and nearly 100% at its Indiana Harbor mill. 4 Most forge shops do not have access to the same type of by-product gas streams, but the principle is relevant: energy-intensive manufacturers can reduce purchased energy by treating waste streams as potential resources. For forging operations, waste heat recovery projects may be more modest, but still valuable. Examples include recuperative burners, regenerative burners, stack economizers, billet preheating, charge preheating, heat recovery from quench systems, or using furnace exhaust for lower-temperature applications elsewhere in the plant. Consider Furnace Upgrades When the Business Case Is Broader Than Fuel Not every energy issue can be solved with tune-ups. Older furnaces may have outdated burners, poor insulation, slow recovery, weak controls, excessive leakage or uneven heating. In those cases, an upgrade may reduce energy use while also improving throughput, temperature uniformity, quality, maintenance and safety.

An example that is particularly relevant to forging is Cleveland Cliffs’ Butler Works project in Pennsylvania. The company announced that, if awarded DOE funding, it would replace two natural-gas-fired high-temperature slab reheat furnaces with four electrified induction slab reheat furnaces. DOE’s project description states that induction heating can reduce energy losses and provide precise temperature control. 5 A steel mill slab reheat furnace is not the same as a forge shop billet furnace. Still, the example is useful because it shows that major steel manufacturers are actively evaluating advanced heating systems not only for emissions reduction, but also for energy efficiency, process control and production competitiveness. For forging producers, the furnace upgrade conversation should include more than fuel savings. A strong business case may also include reduced scale loss, better yield, fewer rejects, faster heat-up, improved safety, lower maintenance costs and improved ability to meet customer sustainability expectations. Use Electrification Selectively Electrification is not a universal answer for forging, but it deserves a serious and practical look in selected applications. Induction billet heating, electric heat treat equipment, resistance heating and hybrid systems may offer advantages depending on part size, material, production volume, utility rates, demand charges and available electrical infrastructure. Induction heating can be attractive because energy is delivered directly into the workpiece, heat-up can be fast, and equipment can often be turned down or shut off more easily than large gas-fired furnaces. It may also reduce floor heat and improve temperature control. However, electrification must be evaluated carefully. Plants need to understand peak demand costs, utility capacity, maintenance requirements, production flexibility and metallurgical requirements. For benchmarking, a useful rule of thumb is to separate energy savings from cost savings. In suitable billet-heating applications, induction heating may use up to 50% less energy than traditional gas furnaces because it generates heat in the billet instead of heating a large furnace chamber, surrounding air and refractory. The cost savings will vary with natural gas rates, electricity rates and demand charges, but the operating savings can also come from faster heat-up, less idle time, reduced scale loss and scrap, better temperature repeatability, and lower heat released to the shop floor. For high-volume, repeat-part lines, those factors may shorten payback and make induction worth modeling even when electricity appears more expensive on a per-unit basis. 10 The right question is not, “Should every furnace become electric?” The better question is, “Where does electric heating make operational and financial sense?” Repeat parts, smaller billets, high-volume lines, precise temperature requirements and applications with high idle losses may be good candidates for analysis. Do Not Ignore Compressed Air Compressed air is one of the most expensive utilities in a manufacturing plant, and it is often one of the least managed. In forging facilities, compressed air may support controls, cylinders, cooling, blow-off, cleaning, instrumentation and other plant functions. Because leaks are invisible and compressors are often located away from production areas, waste can go unnoticed for years.

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ENERGY

The Bottom Line Energy efficiency in forging should not be treated as a side project or a sustainability-only initiative. It is a cost-control strategy, a productivity strategy and a competitiveness strategy. The most practical opportunities usually begin with the basics: measure energy use, focus on furnaces, tune burners, reduce idle time, recover waste heat, fix compressed air leaks, control motors and fans, and build a management system that keeps savings from disappearing over time. For forge shops facing rising costs, workforce constraints, customer reporting expectations and global competition, energy efficiency offers a clear business message: the cheapest unit of energy is still the one you do not have to buy. Thank you to the FIA Energy Subcommittee for their review and contributions to this article. Sources: 1. https://content.govdelivery.com/accounts/USDOEOCED/ bulletins/39265e4 2. https://betterbuildingssolutioncenter.energy.gov/news/better plants-program-partners-save-53-billion-energy-costs 3. https://www.energy.gov/cmei/oced/industrial-demonstrations program-0 4. https://www.clevelandcliffs.com/sustainability/steel-as-a sustainable-material/dept-of-energy-butler-works-project 5. https://www.energy.gov/cmei/oced/industrial-demonstrations program-selections-award-negotiations-iron-and-steel 6. https://en.wikipedia.org/wiki/Cleveland 7. https://www.energy.gov/mesc/industrial-research-and-assessment center-implementation-grant-awards 8. https://www.granges.com/newsroom/in-focus/iso-50001-us/ 9. https://www.energy.gov/mesc/industrial-research-and-assessment center-implementation-grant-awards 10. https://www.cornellforge.com/billet-heating-induction-heating vs-gas-oven-furnaces/

An energy review should include leak detection, compressor sequencing, pressure reduction, receiver capacity and inappropriate uses of compressed air. ENERGY STAR’s industrial resources identify compressed air systems, motors, process heating, pumping and steam as important areas for industrial energy management. 6 For many plants, compressed air improvements offer fast payback. Ultrasonic leak detection, tagging, repair accountability and monthly reporting can turn compressed air from a hidden cost into a managed system. If employees can hear leaks during normal operations, the plant is already paying for wasted electricity. Control Motors, Pumps, Fans and Support Equipment Furnaces may be the most obvious energy users, but they are not the only opportunity. Forging plants run large motors across hydraulic units, cooling systems, dust collection, pumps, fans, cranes and material handling equipment. These systems often run longer than needed or at full speed even when loads vary. Variable frequency drives can reduce energy use on fans, pumps and hydraulic systems where demand changes throughout the day. Preventive maintenance can reduce friction, heat and overloading. Right-sizing equipment and eliminating unnecessary runtime can also help. The key is to evaluate the whole system, not just the motor. Savings come from understanding the motor, drive, controls, load profile, operating schedule and maintenance condition. In many plants, the lowest-cost improvement is simply controlling equipment based on actual demand rather than habit. Build an Energy Management System That Lasts One-time projects are useful, but sustained savings require management discipline. That means assigning responsibility, tracking energy intensity, reviewing performance by production level and making energy part of routine operations. DOE’s Better Plants program reported in 2024 that its partners had achieved $11.8 billion in cumulative cost savings, 2.4 quadrillion Btu in energy savings and 147 million metric tons of avoided carbon dioxide emissions. 7 That scale of savings shows that structured energy management is not theoretical. Large manufacturers are already using it to reduce operating costs. Formal systems such as ISO 50001 and DOE’s 50001 Ready program can provide useful frameworks. Gränges Americas, for example, announced that all three of its U.S. production sites had achieved ISO 50001:2018 certification, supporting continuous improvement in energy performance. 8 Forge shops do not need to overcomplicate the process. A good starting point includes energy data by meter, production-adjusted energy intensity, a list of significant energy users, assigned ownership, management review and a pipeline of projects with estimated savings and payback.

FIA MAGAZINE | AUGUST 2026 13

EQUIPMENT & TECHNOLOGY

THE EVOLUTION OF POWER SUPPLY TECHNOLOGY FOR INDUCTION FORGING SYSTEMS By Joe Stambaugh

I n modern forging operations, production targets continue to rise while energy costs, labor constraints, and equipment uptime requirements become increasingly critical. Induction heating systems have become the preferred method for heating billets and bars because they provide rapid, efficient, and repeatable heating. Behind every induction heating system is a power supply architecture that directly impacts reliability, operating costs, and production performance. More than twenty years ago, I authored a technical paper advocating for Silicon Controlled Rectifiers (SCRs) in the design and manufacture of induction forging heaters. At the time, contemporary analog control boards were simply too slow to protect faster emerging transistor technologies. To overcome this limitation, Ajax TOCCO Magnethermic developed high-speed digital electronics, fiber-optic communications, and advanced protection networks. These innovations fully tamed and leveraged the inherent advantages of modern Insulated Gate Bipolar Transistors (IGBTs). For forging operations, temperature variation is more than an efficiency concern. Inconsistent billet temperatures can lead to poor die fill, increased press loads, accelerated die wear, and greater scrap rates. Modern induction systems powered by IGBT technology help maintain tighter temperature control and improved repeatability throughout production. Today, IGBTs have largely replaced SCRs in high-power switching applications globally. When purchasing induction heating equipment for forging, selecting the right power semiconductor is just as critical as the induction coil design itself. The Medium-Frequency Workhorse Medium-frequency induction heating—typically spanning from 1 kHz to 10 kHz—is the primary workhorse of the forging industry. It provides the deep thermal penetration required for bulk forging, billet heating, bar end heating, and many heating applications. To achieve maximum energy efficiency and system reliability within this band, engineers must balance raw power handling against rapid switching speeds. While legacy devices and ultra-fast alternatives each have their place, the IGBT has firmly established itself as the global industry standard for medium-frequency forging applications, delivering: • Higher Efficiency: Significantly lower operational and switching losses. • Compact Footprints: Smaller inverter designs that fit directly under induction coils. • Reduced Cooling: Minimal thermal management required due to low heat dissipation. • Broad Frequency Range: Seamless, stable operation across the entire medium-frequency spectrum.

• Multi-Band Capability: Single power supplies engineered to run across multiple frequency bands.

Figure 1: A traditional disc-type ("hockey puck") Silicon Controlled Rectifier (SCR) historically relied upon for high-power industrial switching.

Figure 2: A modern, high-capacity industrial IGBT module engineered for high-speed, voltage-controlled efficiency.

Technical Breakdown: Power Semiconductors Head to-Head To understand why the IGBT reigns supreme, we must look at how it compares to alternative silicon technologies across key operational parameters:

14 FIA MAGAZINE | AUGUST 2026

EQUIPMENT & TECHNOLOGY

Parameter

SCR

Power BJT

Power MOSFET

IGBT

400 to 500 Hz

Up to 10 kHz

100 kHz+

1 kHz to 50 kHz Moderate (~3V)

Operating Frequency

On-State Voltage Drop Very Low (< 2V)

Low (< 2V)

High (Load Dependent Losses)

Current Controlled Single pulse turn-on Critical (Unpolarized) 3000 V / 2000 A Minority Carrier Mandatory External

Current Controlled

Voltage Controlled

Voltage Controlled

Control Architecture Drive Requirements Snubber Circuitry

Continuous base drive Continuous gate drive Continuous gate drive

Critical (Polarized) 2 kV / 1000 A Minority Carrier

Often Optional 600 V / 200 A Majority Carrier

Often Optional 3300 V / 1500 A Minority Carrier

Max V/I Ratings

Carrier Type

None

None

None

Commutation Needs Temperature Coeff.

Negative

Negative High Risk

Positive

Flat / Positive Inherently Safe

Thermal Runaway Risk High Risk

Inherently Safe

Requires external equalization

Requires equalizing circuits

Exceptionally Easy

Exceptionally Easy

Parallel Scalability

Eliminating the Rivals: Why Other Devices Fall Short The SCR: Stuck in the Slow Lane Silicon Controlled Rectifiers (SCRs) are the giants of the power world, boasting massive voltage and current handling. However, SCRs are fundamentally limited by slow switching speeds, typically topping out below 1 kHz. Furthermore, they require complex, bulky external commutation circuits just to force the device to turn off. For medium-frequency induction heating, the SCR is simply too slow and architecturally inefficient. The Power BJT: A Thermal Liability The bipolar junction transistor (BJT) can stretch its operation up to 10 kHz, matching the lower boundary of medium-frequency heating. However, it is a current-controlled device that demands a massive, continuous base drive current to stay active. Worst of all, BJTs possess a negative temperature coefficient. As the device heats up, it draws more current, creating a dangerous feedback loop known as thermal runaway that can catastrophically destroy the inverter. The Power MOSFET: Fast but Fragile Power MOSFETs are high-speed champions, effortlessly operating well beyond 100 kHz, making them perfect for high-frequency surface hardening of small components. However, they struggle at medium frequencies due to high conduction losses. While MOSFETs excel at extremely high frequencies, their conduction losses and power-handling limitations often make them less practical for the high-current medium-frequency applications commonly found in forging operations. The Verdict: Why the IGBT Dominates The IGBT is a brilliant hybrid device. It seamlessly blends the best attributes of two worlds: the simple, low-power voltage-gated drive of a MOSFET and the high-current, low-conduction-loss capability of a BJT. • The Sweet-Spot Frequency: The IGBT effortlessly spans the exact 1 kHz to 10 kHz window required for medium frequency applications, with headroom to scale higher if needed.

• Simplified System Footprint: Because it turns off cleanly without forced commutation, engineers can eliminate bulky external circuitry. Snubber networks can also be minimized. • Rock-Solid Thermal Stability: Featuring a flat-to positive temperature coefficient, the IGBT maintains stable performance even as ambient temperatures rise inside a forge shop, thus helping to reduce the risk of thermal runaway. • Modular Scalability: When an induction furnace needs a power boost, multiple IGBT modules can be configured in parallel with minimal balancing effort, allowing for flexible, modular inverter designs. Through continuous R&D, we have perfected this integration. While Ajax TOCCO still designs and manufactures power supplies utilizing legacy architectures where specialized applications demand them, we heavily favor advanced-generation IGBTs for modern forging. For heavy-duty, deep-mass medium frequency industrial heating, IGBT devices dominate as the most efficient, dependable, and cost-effective choice on the market. At one automotive forging facility, an aging SCR-based induction system was replaced with a modern IGBT-driven power supply. The upgrade reduced maintenance requirements, improved heating consistency, decreased energy consumption by 10%, and decreased billet temperature variability to within ±10°C, significantly increasing production uptime. Looking Forward Ceramic high-power Insulated Gate Bipolar Transistors (IGBTs) could be used in the very near future. These are specialized semiconductor devices built on ceramic substrates (like Aluminum Nitride) rather than standard fiberglass. They are widely utilized in heavy-duty power electronics, industrial motor drives, and renewable energy inverters due to their superior thermal management. Advantages • Superior Thermal Conductivity: Ceramic substrates dissipate heat up to 100 times more effectively than standard, keeping high-power junctions stable and preventing thermal runaway.

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