February 2026 Volume 8

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Where Progress is a Tradition

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FIA MAGAZINE | FEBRUARY 2026

PRESIDENT'S NOTE

PRESIDENT'S NOTE

A rtificial intelligence (AI) is becoming ambient. What many don’t yet realize is that the North American forging industry is an essential player in the story of AI’s worldwide transformation. We are changing that narrative. The thunderous AI boom relies on a growing demand for electricity – power that’s generated with forged components that can withstand the extreme forces found in gas, steam, nuclear, hydro, and wind power generation. Once generated, power races along high-voltage transmission lines designed to endure years

Editorial Staff

PUBLISHER & EDITOR Angela Gibian Deputy Chief Executive | Forging Industry Association angela@forging.org ASSOCIATE EDITOR Amanda Dureiko Executive Director (FIERF) | Forging Industry Association amanda@forging.org DESIGN Lorean Crowder | Forging Industry Association Sr. Graphic Design & Publication Specialist lorean@forging.org CHAIRPERSON Jeffrey T. Jones President | Forge Resources Group VICE CHAIRPERSON Paul A. Spitz Vice President - Sales & Marketing | Unit Drop Forge Co. Inc. Antonio Alvarez Division Head | FRISA Steel Robert R. Bolin President | GLAMA USA Inc. Robert Brodhead Plant Manager | American Axle & Manufacturing, Inc. Mark Derry VP Operations | Portland Forge Bret Halley COO | Valley Forge & Bolt Mfg. Co. James D. Kane VP of Commercial Sales | Ellwood Quality Steels Co. Jeff Krueger Exec. Dir. of Corp. Sales | Scot Forge Co. Louis Philippe Lapierre COO | Finkl Steel Jose Lozano Vice President of Operations | Specialty Ring Products, Inc. Matt Natale Executive VP | AML Industries, Inc. Board of Directors

of weather events and stress. This journey of AI’s electric lifeblood along our grid infrastructure is supported by forged components that people, businesses, and the world’s technology leaders rely on to meet their needs, ranging from on-demand entertainment to using AI for lifesaving healthcare discoveries. As artificial intelligence is increasingly woven into the fabric of business and life, the buildout of this new world will be enabled and strengthened by the forging industry. In this edition, we explore many of the interesting applications of AI and automation that are leading the future of the forging industry. • From Simulation to Steel | page 10 • Turnkey Forging Lines For Lightweight Advanced Materials | page 12 • The Impact of AI in Training and Development on Forge Shops of the Future | page 14 • Automating Billet Picking in a Forge with 3D Robot Vision | page 20 • Quantitative Evaluation of Robotic Versus Manual Graphite Lubrication in Metal Forming | page 22 • Manufacturing Automation Systems to Solve Forging Hot Part Inspection Through an Automated Non-Contact System | page 64 As you read through each article, I hope you’re inspired by your fellow FIA members and what we’re accomplishing together. Best Regards,

Mark Ames, AAiP President and CEO Forging Industry Association

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.

FIA MAGAZINE | FEBRUARY 2026 3

CONTENTS

FEBRUARY 2026 | VOLUME 8

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LETTER FROM THE PRESIDENT 3 President's Note WASHINGTON UPDATE 6 Bringing Your Government Dollars Back Home ENERGY 8 Don’t Miss This Big Buying Opportunity EQUIPMENT & TECHNOLOGY 10 From Simulation to Steel 12 Turnkey Forging Lines for Lightweight Advanced Materials 14 The Impact of AI in Training and Development on Forge Shops of the Future

MAINTENANCE 17 How To Perform a Complete Mechanical Press Inspection for a Forging or Stamping Press AUTOMATION 20 Automating Billet Picking in a Forge With 3D Robot Vision 22 Quantitative Evaluation of Robotic Versus Manual Graphite Lubrication in Metal Forming 24 Hope Is Not an Operating Model MATERIALS 29 The Status and Outlook for Forging of High-Entropy Alloy (HEA) Engineered Products for Aerospace, Medical, and Energy Sector Applications OPERATIONS & MANAGEMENT 34 Employee Separations 36 Getting Started in Gage Variation Analysis and Troubleshooting 40 Combating Burn-Out in the Forging Industry 42 Developing the Next Generation of Marketers in the Forging Industry 44 Tired of Dealing with Cybersecurity? You’re Not Alone 46 Leadership, Learning and the Power of Showing up

INDUSTRY NEWS 48 FIA Annual Meeting of Members 51 Marcos Mattiello Appointed President of Gerdau Special Steel North America 52 ONEX, Inc. Expands into New York with Acquisition of Upstate Refractory Services 54 Forging Producers' 2026 Performance will Vary 57 Welcome New Members 58 FIA Upcoming Events FOUNDATION NEWS 60 FIERF Donor Spotlight: GLAMA USA 61 Grace Cantrell Joins Scot Forge FORGING RESEARCH 62 Technical Director Update 64 Manufacturing Automation Systems to Solve Forging Hot Part Inspection Through an Automated Non-Contact System 66 Scientific Use Case : Advanced Microstructural Evolution Prediction MEMBERS SPEAK 72 Inside Sales, Outside Expectations AD INDEX 75 February Advertiser Index

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

FORGING EQUIPMENT & TECHNOLOGY An exploration of the various ways AI, automation and advanced technology are changing the future of forging

Photo Courtesy of Pickit3D

Turnkey Forging Lines For Lightweight Advanced Materials Page 20 The Impact of AI Training and Development on Forge Shops of The Future Page 14 Automating Billet Picking in a Forge With 3D Robot Vision Page 20

For advertising contact info@forging.org

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FIA MAGAZINE | FEBRUARY 2026

WASHINGTON UPDATE

BRINGING YOUR GOVERNMENT DOLLARS BACK HOME By Omar S. Nashashibi

D espite an overwhelming emphasis on tariffs over the past decade, there is more to a manufacturing strategy than trade. As recognized by this administration and others in the past, industrial policy crosses multiple departments and agencies. The website manufacturing.gov identifies ninety-five programs across the federal government to support industry. Manufacturers of all sizes should take a moment to familiarize themselves with opportunities provided by the federal government and key changes in policies that impact their operations. In the past few months, we have seen a flurry of new programs and initiatives announced. On December 19, 2025, the U.S. Department of Labor launched its American Manufacturing Apprenticeship Incentive Fund to encourage employers nationwide to develop, expand, or join existing advanced manufacturing registered apprenticeship programs through a pay-for-performance model. Employers and registered apprenticeship sponsoring organizations are eligible to receive $3,500 for each new apprentice hired. Companies can find a list of eligible occupations, which include maintenance technician, precision machinist, and CNC operator, on apprenticeship.gov. These funds are in addition to $145 million announced on January 6, 2026, to further expand the national apprenticeship system and $98 million for pre-apprenticeship programs targeting 16- to 24-year-olds. Taken together, the actions are a key component of the Trump administration’s initiative to support employers hiring 1 million registered apprenticeships. This is an important distinction – registered versus non-registered apprenticeships. During the first Trump administration, the Department of Labor established a program specifically to support employers employing non-registered apprentices. The exclusive focus on registered apprentices marks a reversal, sending a clear message to manufacturers where the federal government intends to spend its resources. The Small Business Administration is also expanding its focus on manufacturing. Late last year, the SBA approved its initial round of Manufacturers’ Access to Revolving Credit (MARC) loans under the 7(a) program. The loan program is the first ever SBA loan offered exclusively to manufacturers. Businesses may use the MARC loans, which are supported by community and regional banks, for “any short-term working capital need.” Critically, borrowers can combine MARC with conventional commercial loans. Also at the SBA, in support of the Made in America Manufacturing Initiative, the agency awarded $1.1 million in grants to organizations for providing training and technical assistance to support small manufacturers in the SBA’s Empower to Grow (E2G) Program. From a broader policy approach, the Commerce Department’s National Institute of Standards and Technology (NIST), is expanding its efforts by investing millions to establish a center

to advance the use of Artificial Intelligence to boost productivity and increase supply chain resiliency. The AI Economic Security Center for U.S. Manufacturing Productivity is in addition to the expected launch of the AI for Resilient Manufacturing Institute in the coming months. The tax code presents numerous opportunities following the changes in policy for which FIA lobbied in 2025. Last year, Congress passed and the President signed legislation into law that made permanent Research and Development expensing, after 48 percent of FIA members said in a January 2025 survey that they would reduce R&D activities without expensing reinstated. This same law made 100 percent bonus depreciation permanent, increasing the purchasing power of FIA members, one-third of whom reduced capital expenditures due to the depreciation rate falling to 40 percent. To support workforce recruitment and training for manufacturers, the law made permanent the exclusion from an employee’s gross income employer payments towards student loans of up to $5,250 under Section 127 of the Internal Revenue Code. In addition, it expands Pell Grants to short-term, workforce aligned programs of 150-600 hours or 8-15 weeks and also expands Section 529 education savings accounts for “qualified postsecondary credentialing expenses” in connection with “recognized postsecondary credential programs”. As we begin 2026, forging employers should help their workforce better understand the no tax on overtime provision included in the 2025 tax law (Section 70202). Effective 2025 through 2028, individuals with a modified adjusted gross income under $150,000 ($300,000 for joint filers) may fully deduct $12,500 of their overtime, with $25,000 being the maximum annual deduction for joint filers. All these provisions collectively incentivize forging businesses to invest in their facilities, their process, and the people producing forgings on their shop floor. Manufacturers should also look to their state capitals in addition to opportunities from Washington, D.C. Members of the FIA have access to a list of grant programs and tax incentives our firm identifies each month to support manufacturing in America. The Wisconsin Fast Forward program offers up to $400,000 per grantee to reimburse the business for costs of customized occupational training for unemployed, underemployed, and incumbent workers, with applications due February 18, 2026. In Minnesota, employers and associations have until April 30, 2026 to apply for up to $30,000 for a grant program that seeks to aid employers with the development of new registered apprenticeship programs (RAP) or to expand existing programs in apprenticeable occupations. Starting in 2020, Illinois allows on a first-come, first-served basis a tax credit of up to $3,500 for educational expenses for qualifying apprentices, with an additional $1,500 per apprentice if the individual or the employer is located in an underserved area. Ohio’s annual TechCred program reimburses up to $2,000 per

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FIA MAGAZINE | FEBRUARY 2026

WASHINGTON UPDATE

credential for businesses to upskill current or future employees for short-term, industry-recognized, and technology-focused credentials. Policymakers in Washington and around the country are involved in almost every facet of the forging industry. Too often the assumption is action only leads to over-regulation, over-taxation, and government overreach. Taking a different approach to decisions made by elected officials may open new opportunities for businesses. Instead of simply sending money to Washington and state capitals, manufacturers should put your tax dollars back into your shops and communities. Use resources available and the benefits of FIA membership to identify federal, state, and local grant, tax, and other policies that can improve your global competitiveness. China’s “super R&D deduction” allows many of their businesses to deduct 200% of qualifying R&D expenses. That alone should prompt U.S. industry to take advantage of every dollar their government is willing to give back.

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.

NEED A FORGING PRODUCER?

Visit www.forging.org for information on FIA’s FREE Request for Quotation (RFQ) program.

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

FIA MAGAZINE | FEBRUARY 2026 7

ENERGY

DON’T MISS THIS BIG BUYING OPPORTUNITY Natural Gas Prices Reach Lowest Level in More Than a Year By Nancy Gardner

O ver the past year, the experts at Transparent Energy have been advising clients to lock in medium-to-long-term fixed rate supply agreements. We’ve done so because we have extensively studied market volatility and have experienced periods when prices were substantially higher than they are today. In 2022, natural gas prices, a proxy for electricity prices, traded 48.4% higher than in 2025. The difference can substantially impact a business’s bottom line. We also know that low rates will not last forever. Countless factors are driving energy prices, and while it’s impossible to predict when prices will rise, we know that they won’t be getting substantially lower anytime soon. On January 9th, 2026, the 12-month forward natural gas strip closed at the lowest price in over a year. Most of the downward price action was driven by strong gas production and relatively mild weather. But we have seen substantial volatility, particularly towards the front end of the curve. In early December 2025, prompt month natural gas prices reached $5.289 per MMBtu. One month later, that figure fell to $3.169, a more than 40% decline! But prices can only go so low. As we saw in the spring of 2024, natural gas production companies are unwilling to maximize output when prices fall below a certain level.

Source: kansascityfed.org So, what happens when production is flat amid growing demand? In the simplest terms, prices move higher. U.S. energy policy is focused on two primary goals: 1) Increasing LNG exports and 2) Establishing AI superiority. Both targets mean a tightening in the supply/demand balance. NGI forecasts U.S. LNG exports doubling by the end of the decade:

The Kansas City Federal Reserve regularly posts a survey among energy companies tracking production and profitability. There was a substantial decrease in oil and gas production during Q4 of 2025 because of the low-price environment. The most recent survey suggests that profitability starts around $3.80 per MMBtu on average, and it would take a price of $4.89 to substantially increase production. The forecasted range of prices is steadily increasing:

This means substantially less gas being deposited into U.S. storage facilities. In terms of electricity, the Federal Government recently released executive orders to ensure “United States leadership in Artificial Intelligence (AI) will promote United States national and economic security and dominance across many domains.” Achieving this goal is going to be incredibly energy intensive.

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FIA MAGAZINE | FEBRUARY 2026

ENERGY

As we’ve seen in the recent capacity auctions (particularly PJM and MISO), the U.S. electric grid is already severely constrained, and the data center market is poised to increase dramatically, putting even more pressure on the grid. McKinsey & Co forecasts that the U.S. data center market will grow from 17 GW to 35 GW by the end of 2030 (equivalent to adding the entire state of New York to the power grid). While much of the near-term price volatility has been weather driven, the long-term fundamentals clearly point in a bullish direction. With the recent dip in energy prices, and regulatory and market-driven changes afoot, now is a wonderful time to be buying long-term inexpensive electricity and natural gas.

If you are interested in capitalizing on this time-sensitive buying opportunity and/or are looking for help understanding the energy markets and executing an energy-procurement strategy that limits your cost and risk, contact Transparent Energy at ngardner@transparentedge. com.

FIA MAGAZINE | FEBRUARY 2026 9

EQUIPMENT & TECHNOLOGY

FROM SIMULATION TO STEEL How Upstream Decisions Shape Forging Tooling By Bailey Taylor

W hen forging technology comes up in conversation, most people picture the forge floor first. Presses cycling, dies heating, billets moving. This is where forging feels most tangible, and it is also where most issues tend to surface. When something goes wrong, it usually shows up here in the form of fill problems, excessive flash, premature wear, or inconsistent parts. What is easier to overlook is how many of those issues were set in motion much earlier, during tooling design and build. If you spend time on the tooling side, it can become clear quickly that a forging program can start going right or wrong well before the first part is run. Things like how long a die lasts, how well a part fills, and how smoothly start-up goes usually trace back to decisions made much earlier in the tooling process. Over time, improvements in software, machining capability, and inspection have shifted tooling work away from reacting to problems and more toward preventing them. The result is not always dramatic, but it is noticeable over the life of a program. Simulation Software: Working Out the Questions Before Steel is Cut Simulation software has been around in forging for years, but its role has become more practical and less theoretical. Instead of being used to explain why something went wrong after the fact, it is now commonly used to answer questions early, when changes are still manageable and relatively low risk. Looking at how material moves, where heat builds, and where stress concentrates during design gives a good sense of where a die is likely to be touchy. Spots that are prone to underfill, heavy flash, or localized loading usually stand out early when you start looking at a model this way. These are often the same areas that would later require hand work, weld repair, or repeated adjustments once the die is in production. At that stage, changing a radius, tweaking draft, or adjusting a preform is generally a manageable exercise. Those changes can be evaluated quickly and fed back into the design without major disruption. Once a die has already seen press time, making those same changes becomes a much different and usually more painful task. What started as a small design adjustment can turn into added machining time, lost production, and another round of tryouts. In day-to-day terms, this often means fewer surprises at the press. Simulation does not eliminate tryouts entirely, but it often reduces their scope and helps get to stable production with fewer iterations. Instead of chasing several unrelated issues at once, teams can focus on fine tuning rather than fundamental corrections. Over multiple programs, that difference adds up. CAM Software: Letting the Die Be What it Was Designed to Be A good design still depends on how well it can be machined. No matter how sound a model looks on screen, it has to be turned into steel

accurately and consistently. This is where CAM software has made a noticeable difference, even if it is not always obvious from the outside. Modern toolpath strategies allow complex geometry to be machined more consistently than in the past. Deep cavities, blended transitions, and contoured surfaces that were once softened or simplified to make machining easier can now be produced closer to their intended shape. In forging dies, those details matter. Subtle differences in surface shape can influence material flow and wear more than expected. Small surface inconsistencies have a way of showing up later as wear, flow problems, or extra maintenance. A die that fills unevenly or wears faster in one area often traces back to geometry that was difficult to machine consistently. CAM software helps reduce that variability by controlling how tools engage the material and how surfaces are finished. Consistency also matters when tooling needs to be replaced. Being able to reproduce geometry with minimal variation helps keep forging behavior predictable, rather than forcing teams to rework adjustments that were already solved on an earlier build. When replacement tooling behaves similarly to the original, startup is smoother and fewer changes are required at the press. CNC Machining Centers: Turning Capability Into Repeatability Advances in machining centers have reinforced what modern CAM systems make possible. Increased rigidity, better spindle control, and improved coolant delivery all contribute to more stable machining, especially in hardened materials commonly used for forging dies. Multi-axis capability has also reduced the number of setups required on many forging dies. Fewer setups generally mean fewer opportunities for small alignment errors to accumulate. Over multiple builds, this starts to show. Dies tend to behave more alike, wear patterns become easier to anticipate, and corrective work is usually more limited. From the forge’s point of view, this does not always appear as a dramatic improvement in one specific area. There may not be a single change that stands out. More often, it shows up as fewer small issues that used to be accepted as part of the process. Less spotting, fewer unexpected adjustments, and more consistent startup behavior all point back to repeatability in how the die was machined. As machining capability has improved, expectations have shifted as well. Holding intended geometry is no longer the exception. It is increasingly the baseline, and that has changed how tooling performance is judged over time. 3D Inspection: Knowing What You Actually Have As die geometry has become more complex, inspection methods have had to keep pace. Traditional inspection tools still play an important role, but they are often focused on individual features

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EQUIPMENT & TECHNOLOGY

rather than the full surface. While those checks are necessary, they do not always tell the full story. Three-dimensional inspection makes it possible to compare entire surfaces back to the original model. This helps reveal deviations that may not be obvious when checking only a few locations. In forging dies, subtle differences in surface shape can influence material flow and wear more than expected. Being able to see those differences across the full cavity provides a clearer picture of what was actually produced. Inspection data also becomes a reference over time. When tooling is repaired or duplicated, having a clear record of what was actually built helps maintain consistency across programs. Rather than relying on assumptions or tribal knowledge, teams can reference measured data and make informed decisions. As traceability and documentation continue to gain importance, this level of inspection has become a more routine part of quality tooling work rather than a specialized extra. It supports repeatability and helps close the loop between design, machining, and performance at the press. Conclusion: Setting the Process Up to Behave Forging performance is judged at the press, but many of the conditions that drive that performance are established earlier. How predictable production ends up being has a lot to do with the tools used to design the die, cut it, and verify what was actually built. When uncertainty is addressed early, machining processes are capable of holding the intended geometry, and inspection confirms

what was produced. Tooling shifts from fixing problems to preventing them. From our side of the process, that change has made forging outcomes more consistent and easier to manage over time. In that sense, forging technology extends well beyond the forge floor. Tooling plays a central role in how effectively it all comes together, long before the first billet ever reaches the press.

Bailey Taylor Sales Associate

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

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EQUIPMENT & TECHNOLOGY

TURNKEY FORGING LINES FOR LIGHTWEIGHT ADVANCED MATERIALS By Karissa Krueger

T he automotive industry is in the midst of a profound transformation. Electrification, sustainability mandates, and consumer expectations for improved fuel efficiency are reshaping vehicle design and manufacturing. At the center of this evolution lies a critical engineering challenge: lightweighting. Reducing vehicle weight is no longer optional; it’s essential for meeting stringent emissions standards, extending battery range, and enhancing overall performance. Every kilogram saved translates into measurable gains in efficiency, whether for internal combustion engines or electric vehicles. For EVs specifically, lightweighting directly impacts battery size and range, making it a cornerstone of modern automotive manufacturing. Achieving these benefits without compromising strength and durability requires advanced materials such as aluminum and high-strength steels, combined with precise manufacturing processes. Forging has emerged as a key technology for lightweighting as it delivers superior mechanical properties, fatigue resistance, and dimensional accuracy. However, producing lightweight components at scale introduces new complexities, including tighter tolerances, intricate geometries, and the need for rapid cycle times. These challenges demand a new approach — one that integrates technology, automation, and process expertise into a single solution. This is where turnkey forging lines become imperative.

Inside a Modern Forging Line A turnkey forging line is much more than a collection of machines. It is an integrated ecosystem designed for efficiency, consistency, and adaptability. These lines combine presses, automation, furnaces, and digital controls into a seamless workflow that minimizes downtime and maximizes output. Take the production of lightweight aluminum suspension or chassis components as an example. Billets must be heated to precise temperatures, pre-formed where necessary, and transferred quickly and reliably through multiple forming stages. Any disruption — temperature variation, mistimed handling, or positioning errors — can affect part quality and scrap rates. In a turnkey line, these steps are synchronized through automation and digital monitoring, allowing high-volume production without sacrificing consistency. Automation is the backbone of these systems, but different applications call for different solutions. Conventional industrial robots offer flexibility and are often cost-effective, but they can become a bottleneck in very high-output lines. More advanced solutions, such as mono beam and walking beam systems, provide faster and more precise handling, making them ideal for crank and screw presses. At the forefront of automation technology is the Tri-Axis Servo Transfer system developed by ANDRITZ Schuler. This system delivers maximum positioning accuracy and reliability, enabling optimized forming, cooling, and spray processes. Servo-driven solutions reduce cycle times without compromising quality, making them particularly well-suited for automotive lightweighting programs where precision and speed are paramount. Real-World Impact The benefits of turnkey forging lines are not theoretical — they are already delivering results in forge shops worldwide. One notable example is the GLF 5,000-ton turnkey line developed for a Tier 1 supplier. This fully automated system followed the successful implementation of a GLK 2,500-ton turnkey line for the same customer. Both lines are in operation and have increased the manufacturer’s production capability for several aluminum suspension parts, including wishbones, swivel bearings, and similar forgings. Operator involvement is minimal, limited primarily to monitoring, thanks to advanced automation and digital controls. The result is consistent quality, reduced scrap, and faster time-to market, demonstrating the transformative potential of turnkey solutions.

ANDRITZ Schuler is a one-stop, one-source supplier for forging presses, hammers, and counter blow hammers, process and operational development, dies, and automation systems.

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EQUIPMENT & TECHNOLOGY

ANDRITZ Schuler exemplifies this approach, delivering complete forging solutions tailored to customer needs, whether for cold, warm, or hot forging applications. The company’s capabilities span a wide range of technologies, including mechanical and hydraulic presses, screw presses with direct drive, and forging hammers. Energy-saving technologies like ANDRITZ Farina’s KERS reduce power consumption and improve sustainability. A global service network provides comprehensive support to maximize uptime and extend equipment life. These turnkey solutions enable manufacturers to meet one of the automotive industry’s most pressing challenges: producing lightweight, high-strength components efficiently and sustainably. The Road Ahead Lightweighting will continue to shape automotive manufacturing. As vehicles become more electrified and regulations tighten, the demand for precision-forged aluminum and steel components will only grow. Turnkey forging lines, automation, energy efficiency, and digital intelligence are the key to staying competitive in this dynamic landscape. With ANDRITZ Schuler as a partner, forgers gain more than equipment — they gain a pathway to innovation, sustainability, and long-term success. ANDRITZ GROUP International technology group ANDRITZ provides advanced plants, equipment, services, and digital solutions for a wide range of industries, including pulp and paper, metals, hydropower, environmental, and others. Founded in 1852 and headquartered in Austria, the publicly listed group employs about 30,000 people at 280 locations in over 80 countries. As a global leader in technology and innovation, ANDRITZ is committed to fostering progress that benefits customers, partners, employees, society, and the environment. The company’s growth is driven by sustainable solutions enabling the green transition, advanced digitalization for highest industrial performance, and comprehensive services that maximize the value of customers’ plants over their entire life cycle. ANDRITZ. FOR GROWTH THAT MATTERS. ANDRITZ METALS ANDRITZ Metals is – via the ANDRITZ Schuler Group – one of the world’s leading suppliers of technologies, plants, and digital solutions in metal forming. The product portfolio also includes automation and software solutions, process know-how, and service. In the metals processing segment, the business area offers innovative, sustainable, and market-leading solutions for the production and processing of flat products, for welding systems and furnaces with its own burner solutions, as well as services for the metals processing industry. Karissa Krueger Sales & Marketing Specialist ANDRITZ Schuler Incorporated Email: karissa.krueger@andritz.com

ANDRITZ Farina’s scotch yoke presses (GLK and GLF series) do not require connecting rods, unlike conventional forging presses. This allows for lower builds and the system’s all-around closed body achieves high rigidity values. The raised guides also allow for high off-center forces during the forging process. A Hidden Advantage Lightweighting is often discussed purely in terms of vehicle performance, but sustainable manufacturing matters just as much. Forging is energy-intensive, and rising energy costs are forcing manufacturers to look closely at how power is consumed on the shop floor. Innovative drive concepts are making a true difference here. ANDRITZ Farina, a subsidiary of ANDRITZ Schuler, offers the Kinetic Energy Recovery System (KERS), which combines conventional and servo drive technology to significantly reduce power demand. In practice, KERS can reduce power consumption by up to 40 percent while achieving speeds of 30 strokes per minute. The dual benefit of lower operating costs and higher productivity makes KERS-equipped presses a “game-changer” for modern forge shops. In an industry where sustainability and efficiency are increasingly linked, energy-saving technologies like KERS provide a competitive edge. Why Turnkey Matters Managing multiple suppliers for presses, automation, and service can lead to delays, miscommunication, and higher costs. A single-source, turnkey provider simplifies it all. With one partner responsible for the complete line, projects move faster, components are designed for integration, and comprehensive support ensures manufacturers have access to expertise throughout the lifecycle of their equipment.

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EQUIPMENT & TECHNOLOGY

THE IMPACT OF AI IN TRAINING AND DEVELOPMENT ON FORGE SHOPS OF THE FUTURE By THORS eLearning Solutions

A s one of the oldest and most reliable manufacturing little over time. Yet the industry itself is anything but static. Competitive pressures, workforce demographics, and expectations around productivity and consistency continue to rise. Forging leaders routinely evaluate investments in equipment, tooling, and process improvements to meet these demands, but what is less visible, but equally critical, is employee development – evolving how people learn and how knowledge flows through the organization. Structured training programs are designed to develop people’s skills, which in turn directly influence quality, safety, production, and risk. As modern-day AI (artificial intelligence) tools like ChatGPT, Gemini, Claude, CoPilot and others become a normal part of how people learn and solve problems, the cost of relying solely on traditional or conventional training approaches is becoming harder to ignore. With new classes of AI tools emerging and advanced AI capabilities now embedded in many commercial LMS platforms, the question for forging organizations is no longer whether AI-powered learning solutions are too futuristic for this industry. It is whether organizations can afford not to adapt as employee learning behavior itself changes. There are many benefits to be gained from adding AI-based learning tools to the forging work environment, which we’ll explore in this article. Learning Behavior Has Changed, While Training Systems Have Not Outside the workplace, many employees already rely on AI tools to answer questions, summarize information, and explore cause-and effect relationships. For new workers entering forging roles, this behavior is not new or experimental; it has become normal and natural. When new employees encounter shop-floor training systems built around printed materials, physical manuals, or scattered digital files, friction appears. Initially, this shows up as lost time spent searching for answers or seeking help from a knowledgeable co worker. Over time, it becomes a deeper issue. Employees either accept “time-outs” for knowledge retrieval as standard operating procedure or they develop informal workarounds to get the information they need. These all-too-common “blind spots” reflect a growing gap between how people expect to learn and solve problems – and how organizations provide information. When internal systems are difficult to navigate, employees do not stop learning – they simply look elsewhere. Let’s look at ‘Closed-Die Forging’ as an example because it is widely used on shop floors. processes, the fundamentals of forging – such as controlled deformation, heat, force, and material flow – have changed

Typical shop-floor challenges New operators often learn the sequence of steps quickly: billet heating, placement, press operation, and part removal. What takes much longer to develop is the understanding behind those steps. How billet temperature affects die fill. How forging force influences flash formation. How lubrication impacts die life. This difference – between knowing what to do and understanding why – matters. Operators who lack cause-and-effect understanding may struggle when conditions change, defects appear, or equipment behaves unexpectedly. Traditionally, this knowledge develops slowly through experience, trial and error, and mentoring. While effective, this approach consumes time, scrap, and supervisory resources, putting a strain on limited resources. In contrast, AI-powered learning tools offer a way to accelerate this understanding without increasing production risk. Why Traditional Training Struggles to Scale Conventional forging training relies heavily on experience. Shadowing and mentoring new team members remains essential, but it can be difficult to scale this model consistently across shifts, facilities, and workforce turnover. Documentation helps standardize expectations, but static instructions are unable to convey dynamic processes such as metal flow or defect formation. Manuals explain procedures, but they rarely build intuition. As a result, learning often remains reactive – focused on trial and error to gain experience, and correcting problems after they occur rather than preventing them. With AI-powered learning solutions, hands-on training is paired with a learning layer that allows operators to explore processes, visualize outcomes, and build their decision-making skills before mistakes occur on the shop floor. Practical Applications of AI in Closed-Die Forging Training The following examples illustrate how AI-powered learning tools can support closed-die forging training in practical, shop-floor relevant ways. 1. Parameter–Effect Exploration AI-based learning tools allow learners to explore parameter effects virtually by enabling them to adjust variables such as billet temperature, forging force, lubrication level, and die alignment and immediately see the impact. Outcomes such as underfill, excessive flash, or die damage can be explored virtually using AI. This approach builds cause-and-effect understanding rather than rote memorization. Operators develop intuition that helps them respond more effectively to real-world variability – without scrap or downtime.

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(ChatGPT), Google (Gemini), Anthropic (Claude), and Microsoft (Copilot) can be purchased and installed inside a company firewall to secure and protect any proprietary knowledge and information that’s shared. When properly implemented, this type of AI assistance can reduce risk by consistently surfacing approved procedures, specifications, and vetted institutional knowledge. The Strategic Cost of Losing Control of Organizational Knowledge Forging is a knowledge-intensive industry. Decisions related to die wear, press behavior, and process sequencing reflect years of experience. When the appropriate subject matter experts are not accessible – or if they retire – the company stands to lose the context, judgment, and continuity of their decision-making rationale. AI assistants and AI-powered learning tools cannot replace expert judgment, but they can make that judgment accessible and reusable. The greatest cost of doing nothing is not measured in training hours, but in the gradual loss of control over how knowledge is shared and applied. For forging leaders, the question is no longer whether or not AI-powered learning tools have an important role to play in employee training and development. The choice is whether to proactively embrace AI tools to shape employee learning and knowledge sharing – or allow that decision to be made informally, one workaround at a time. Final Takeaways AI-powered learning does not replace experience – it harnesses the knowledge that’s already there. By providing a way to capture and share the valuable knowledge the company has built up over time, AI learning tools democratize access to expertise. When considering whether AI-powered learning tools are right for your organization, here are the key factors to remember: • Workforce learning has changed faster than traditional training systems. • AI-powered learning tools help operators build cause-and effect understanding without scrap or downtime. • When properly used, AI tools can reduce risk by keeping learning aligned with approved processes. • The greatest risk is not adopting AI but losing valuable knowledge that benefits the wider organization. In forging, knowledge has always been a competitive advantage. Using AI-powered learning tools helps companies leverage their knowledge as an asset, while ensuring that it remains controlled, accessible, and scalable, so that organizations can thrive and employees can excel. About THORS eLearning Solutions: THORS eLearning Solutions is a leading global provider of online technical courses and AI-powered productivity tools specifically designed for the manufacturing industry. Founded in 2010, THORS eLearning Solutions has been transforming manufacturing education through THORS Academy, a visually engaging and ever-expanding eLearning library of over 230 expert-developed courses. Covering topics from manufacturing fundamentals and materials to quality standards and emerging technologies, THORS Academy empowers professionals to increase their knowledge base to keep up with today’s fast-paced manufacturing

2. Visual Demonstration of the Forging Sequence Certain aspects of forging, such as internal metal flow and die cavity filling, are difficult to observe during production. AI-driven visual demonstrations address this gap by showing animated simulations of the forging sequence. Operators can replay steps, isolate stages, and explore “what if” scenarios. For example, seeing how insufficient billet temperature leads to underfill reinforces concepts that are difficult to convey through text alone. It’s like having instant, interactive video replays – directly in the flow of work. 3. AI-Based Defect Recognition Training Defect recognition is a skill typically built through experience. AI-based learning tools accelerate this process by presenting real images of forged parts and prompting learners to identify defects, probable causes, and corrective actions. This reinforces the connection between process variables and outcomes, strengthening diagnostic judgment on the shop floor. 4. Voice-Based AI Assistants Voice-based AI assistants allow operators to ask questions in plain language and receive concise explanations supported by images or short clips. This type of “hands-free” interaction is especially valuable in fast-paced environments – or for operators with limited English reading proficiency. By reducing reliance on manuals or informal guidance, these tools help standardize understanding without slowing production. 5. Skill-Level Adaptive Learning AI-powered learning tools can adjust content based on the learner’s experience level. New operators can focus on fundamentals, while more experienced personnel can explore more advanced skills such as process control, defect prevention, and die wear considerations. This allows a single system to support multiple roles, reducing the need for separate training tracks. The examples outlined above show how AI-powered learning tools can support learning at the individual skill level, making employees more efficient, confident and empowered. Moreover, giving employees easy access to accurate, approved knowledge not only improves overall efficiency, but also has direct consequences for consistency, safety, and risk across the operation. When Access to Knowledge Falls Behind, Risk Increases When access to accurate, approved information is inconsistent, variability follows. Operators rely on memory, coworkers, supervisors, outdated files, or whichever source is most readily available. When SOPs change, different teams or shifts may unknowingly work from obsolete/outdated versions of procedures or specifications. Over time, the impact of information gaps can compound – increasing rework, complicating audits, and introducing risk that is difficult to trace back to a single cause. As all-purpose AI tools like ChatGPT, Claude, Gemini and others become common outside the workplace, another risk emerges. Employees may turn to these tools for explanations – without knowing whether the information they provide aligns with company-specific standards or safety requirements. The issue is not the AI tools themselves, but the lack of control over how knowledge is accessed and applied to company-specific challenges. Commercially available AI tools from companies like OpenAI

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environment. To date, over 250,000 manufacturing professionals worldwide have advanced their expertise using THORS Academy. The company’s newest offering, MFG Genius, is a powerful generative AI assistant providing technical knowledge on demand at the point of need. Trained on the vetted manufacturing knowledge of THORS Academy, as well as customer-supplied content, MFG Genius enables manufacturing teams to quickly resolve production challenges and optimize operational efficiency —all while supporting continuous improvement initiatives. Trusted by Fortune 500 companies and their Tier 1 and Tier 2 suppliers across a diverse array of manufacturing sectors, THORS eLearning Solutions helps organizations boost productivity, empower learners, and optimize decision-making, while saving time and money. Learn more at www.thors.com. Senthil Kumar Founder and CEO THORS eLearning Solutions Phone: 330-576-4448 Email: senthil.kumar@thors.com

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HOW TO PERFORM A COMPLETE MECHANICAL PRESS INSPECTION FOR A FORGING OR STAMPING PRESS By Jeff Fredline MAINTENANCE

U nderstanding the condition of your press equipment is increasingly important. If you don’t take the time to schedule inspections, your equipment will schedule them for you. This article provides a complete step-by-step procedure for inspecting a mechanical forging or stamping press. Keep in mind that a press is designed to provide: • Repeatable tonnage (force) • A perfectly square environment in which the tooling can operate Approaching the inspection process with these two factors in mind helps explain the “why” and “how” behind each check. Performing a complete inspection requires the following equipment: 1. Hydraulic or mechanical jacks large enough to lift the weight of the ram assembly, crankshaft, and gearing 2. Measuring tools such as dial indicators with magnetic bases and feeler gauges 3. Flashlights or other appropriate lighting for the inspection process 4. An inspection form for recording critical data discovered during the inspection Accurate recording of inspection results is critical to the process. Step 1 — Prepare Your Press for Inspection Clean up the area around the machine to allow access to all areas. Place the ram at bottom dead center and perform lockout/tagout procedures. Turn off the air pressure to the machine and exhaust the air from the air counterbalance system. Turn off any hydraulic systems. Special Note: If you are inspecting a mechanical stamping press equipped with hydraulic overloads in the ram assembly, leave air pressure to the overloads on so the hydraulic overload cylinders are engaged. This will allow you to obtain more accurate lift clearance readings when measuring bushing wear. Step 2 — Check Vertical Lift Clearances Place a hydraulic jack on the centerlines of the die space (left to right and front to rear). If you must use shimming blocks to build up the height of the jack, use steel or aluminum blocks. Do not use wood; it can flex under jack pressure and affect readings. Place one dial indicator and base on top of the bolster plate next to the jack. This indicator will be used to measure total lift clearance and to show when all clearances have been removed during jacking. It is best to use an indicator with 1 in. of travel. Adjust the indicator so you have at least 0.500 in. of travel as the ram assembly is lifted.

Apply pressure with the jack until the needle on the indicator stops, then record the total movement in thousandths of an inch. This value is the total lift clearance for the machine. Record it on your inspection documents. Next, measure clearance at the next connection point (for most machines, the wrist-pin bore). Place a second indicator and magnetic base to measure from the upper connection to the ram, leaving the original indicator next to the jack. Once the indicator between the upper connection and the ram is in place, zero it and repeat the jack test. Watch the indicator between the upper connection and the ram and record the reading. Next, measure the clearance between the upper connection and the crankshaft bushing. Move the indicator from the upper connection to ram position to the upper connection-to crankshaft position, then repeat the jack procedure and record the measurement. The final vertical-lift-clearance measurement is clearance in the main bushings. Check both the left-hand (LH) and right-hand (RH) main bushings. Use an additional indicator and base—one between the crankshaft and the frame on the LH side and one on the RH side. Using the jack, repeat the lifting procedure and record the readings for both sides. Example: 1,000-ton press • Total lift clearance: 0.210 in. • Upper connection to ram: 0.065 in. • Upper connection to crankshaft: 0.086 in. Figure 1 shows the layout of a mechanical stamping press. Forging presses are similar, but they do not use the nut housing assemblies. They still use a wrist-pin-and-bushing arrangement to attach the ram to the upper connection. Because the ram and connection assembly can shift slightly, the individual connection point readings may not add up exactly to the total lift clearance. It is also common for the main bushing on the bull-gear side of the press to show slightly more wear due to the weight of the gear and clutch assembly. The next step is to determine whether the clearances detected are within acceptable running tolerance. For rotational clearance in a press, the standard running clearance is 0.001 in. per inch of shaft or pin diameter up to 12 in. diameter, and then 0.0005 in. per additional inch over 12 in. Example: 24 in.-diameter shaft • 24 in. - 12 in. = 0.012 in. clearance • Plus 12 additional inches at 0.0005 in. per inch = 0.006 in. • Standard tolerance for 24 in. rotational clearance: 0.018 in. • Main bushings (RH): 0.045 in. • Main bushings (LH): 0.038 in.

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