May 2025 Volume 7

Finkl Steel finkl.com

Booth 329

LETTER FROM THE EDITOR

Welcome to the May Issue of FIA Magazine , where we shine a spotlight on the evolving landscape of forging automation and material

is a gateway for young minds to discover the fascinating world of metal forging. Congratulations to the FIA/FIERF team and FIERF leadership on this achievement! (Page 80) Additionally, we recognize the ongoing challenges and opportunities in the global trade environment. The current state of trade and tariffs in North America continues to be a pressing issue for our industry. As international competition intensifies and policies shift, FIA is actively working alongside our members and lobby firms to advocate for fair trade policies, tariff relief, and competitive conditions that support North American forging operations. Ensuring that our manufacturers can compete on a global scale remains a top priority, and we are committed to engaging with policymakers to protect and strengthen the forging sector. (Page 4) As always, we hope you find this issue both informative and inspiring. The forging industry is evolving rapidly, and staying ahead requires adaptability, innovation, and collaboration. Whether you are exploring new automation technologies, planning for the next generation of leaders, or celebrating the accomplishments of our community, FIA remains committed to supporting your journey. Thank you for being a part of this vital industry and for your continued engagement with FIA Magazine and the Forging Industry Association.

handling. The forging industry continues to embrace innovation at an unprecedented pace, and this issue explores the transformative power of automation—its role in enhancing efficiency, improving safety, and shaping the future of manufacturing. Among the features in this issue is an insightful look at automated welding and its growing adoption in forging operations. As companies seek ways to optimize production, robotic welding systems are proving to be a game-changer, offering precision, consistency, and improved throughput. (Page 23) Similarly, we explore automation in material handling, where smart systems and robotics are reducing manual labor and increasing overall operational efficiency. These advancements are not just about technology; they are about enabling a safer, more productive work environment for the skilled employees who drive our industry forward. (Page 38) In addition to technological advancements, this issue addresses the critical topic of succession planning in manufacturing. As industry veterans retire, ensuring a seamless transition of knowledge and leadership is more crucial than ever. An article from Jared Detter explores best practices for developing the next generation of leaders, providing actionable insights for businesses looking to secure their long-term success. (Page 48) On the organizational front, we are excited to celebrate Amanda Dureiko's appointment as the new Executive Director of the Forging Industry Educational and Research Foundation (FIERF). Amanda’s leadership and vision will undoubtedly continue to strengthen FIERF’s mission of supporting research and education in forging, ensuring that our industry remains innovative and competitive. (Page 84) We are also thrilled to share that the FIERF children’s book, Forging with Freddy , has won a 2025 TRENDY Award for Best Book/Publication. This recognition underscores the importance of outreach and education in inspiring future generations about the world of forging. Forging with Freddy is not just a book; it

Best regards,

Angela Gibian, CAE Publisher/Editor, FIA Magazine Interim President & CEO, FIA

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

Board of Directors

Antonio Alvarez Robert R. Bolin Robert Brodhead

James D. Kane Jeff Krueger Louis-Philippe Lapierre Jose Lozano Matthew Natale

DESIGN Lorean Crowder lorean@forging.org

CHAIRPERSON Jeffrey T. Jones VICE CHAIRPERSON Paul A. Spitz

Mark Derry Bret Halley

FIA MAGAZINE | MAY 2025 1

CONTENTS

MAY 2025 | VOLUME 7

MAINTENANCE 20 How to Justify the Repair or Replacement of Your Forging Presses AUTOMATION 23 Automated Robotic Welding System 26 Forging to the Last Billet 30 Automation Enhances Surface Finishing in the Forging Industry 32 Automation and Tool Management 34 Planning for Automation? Start with the Parts 36 Driving Robotics Innovations in Casting and Forging for Defense Through Collaboration 38 You Don’t Have a Labor Shortage. You Have an Automation Problem 42 Case Study: Automotive Parts Manufacturer Streamlines Production With 3D Robot Vision MATERIALS 44 Advanced Materials & Forging OPERATIONS & MANAGEMENT 46 Employment issues – What’s the current state of the law? 48 The Science of Succession Planning 52 Addressing Workforce Challenges in Casting and Forging 54 Tech Talk: Simplifying Frequently Used Terms 56 Bringing Experiences to Light through a Survey of Women in Forging 60 Anchor Harvey Announces Integration with PMG Family of Businesses

INDUSTRY NEWS 62 U.S. Manufacturers Expect Profit to Increase Despite Tariffs 65 FIA and FIERF Announce 2025– 2028 Board Officers and Trustees 66 Welcome New Members 69 FIA Announces 2024 Safety Award Winners 71 Chiz Bros. Acquires Advanced Material Science to Bolster Insulation Machining Services 72 FIA 2025 Annual Meeting of Members Recap 74 Member Spotlight: Patriot Forge 76 Milwaukee Forge In A State Court Receivership Proceeding 77 Remembering Lyle D. Sharp, Former FIA President 78 FIA Upcoming Events FOUNDATION NEWS 80 FIERF Children's Book 'Forging with Freddy' Wins 2025 Trendy Award 82 FIERF Donor Spotlight: Silent Auction Donors 83 Letter from the Technical Committee Chair 84 Amanda Dureiko Named Executive Director of FIERF Forging Foundation FORGING RESEARCH 86 FIA Technical Update: Shifting Seasons, Opportunities, and Project Updates MEMBERS SPEAK 88 Embracing Leadership Development in the Forging Industry AD INDEX 89 May Advertiser Index

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LETTER FROM THE EDITOR 1 Letter from the Editor WASHINGTON UPDATE 4 Tariffs Today, Taxes Tomorrow: Manufacturers Plan for Both ENERGY 6 Energy Prices Rising Fast: Why a Big Upward Revision Is Raising Concerns for 2026 EQUIPMENT & TECHNOLOGY 9 Minimize Delays & Maximize Savings With Turnkey Forging Lines 12 The Benefits of OEM Rebuilds and Updates for Hydraulic & Mechanical Forging Equipment 14 Pushing the Limits of Forging 16 The Elephant in The Room – What Does Industry 4.0 Really Mean in the Forging Industry?

For advertising contact info@forging.org

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

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TARIFFS TODAY, TAXES TOMORROW: MANUFACTURERS PLAN FOR BOTH By Omar S. Nashashibi WASHINGTON UPDATE

A s I write this on Tax Day, April 15, 2025, my inbox is flooded with questions about tariffs. Not about the $4.5 trillion in tax increases coming on January 1, 2026, not about the tax hike planned for small businesses in just 261 days, and not about the hundreds of thousands in added taxes manufacturers will pay this year on their R&D activities. All tariffs, all the time. Taxes are so tomorrow. That tomorrow is already here, and not just for those of us who make quarterly payments to the IRS. Tariffs and taxes clearly interact as some lawmakers are relying on the revenue from import duties to offset a portion of the costs associated with extending the Tax Cuts and Jobs Act of 2017. In April, the House and Senate passed their budget resolutions setting up a critical process in the U.S. Senate known as reconciliation. Unlocking this budgetary procedure permits Republicans to pass a tax, energy, immigration, and security package costing trillions of dollars, with only fifty votes in the U.S. Senate, instead of the typical sixty. This all but guarantees congressional Republicans in charge of both chambers will send President Trump a package of tax cuts this year – the question is for whom will lawmakers cut taxes, for how long, and how much it will cost? We had many of these same questions in 2017, when the GOP also controlled all of Washington and passed a $1.2 trillion tax bill. That law permanently lowered the C-Corporation rate to 21 percent from a near global high of 35 percent; created a 20 percent deduction called Section 199a for passthrough businesses paying at the owner’s individual rates; and provided manufacturers with four years of full and immediate expensing of their R&D activities and five years for capital expensing. As a tax lobbyist on that legislation at the time, manufacturers inundated me with questions. When will the tax provisions take effect? When should I place orders for new machines? Should I start hiring in anticipation of customers flooding me with orders? All very valid, and optimistic, questions. Today, few if any come my way on major tax legislation that may change the way manufacturers do business in the U.S. for the next decade. Of course, that pales in comparison to how tariffs may change the way manufacturers do business globally for the next generation. As is the case with all tax legislation, this reconciliation measure must start in the U.S. House of Representatives, where the Speaker of the House set an ambitious timeline to complete their version of the bill prior to the Memorial Day break. Sources in Washington, however, believe that the process to pass a bill, which may exceed $7 trillion and cover politically sensitive topics such as

immigration, the border, and energy will take months, not weeks. In our conversations with policymakers, we do expect an “R&D fix”, removing the requirement to amortize R&D expenses, however, it may not extend retroactively beyond January 2025. Many FIA members report Bonus Depreciation, the 100 percent deduction for capital expenses, as their top tax priority. That level dropped this past January to 40 percent and restoring full expensing is a traditional stimulus for manufacturing, prompting businesses to spend millions. As with R&D, retroactivity for 100% expensing likely only reverts to January 2025, not to 2023 when the provision began to phase down. An extension of the 199a deduction for passthroughs is also on the table ahead of its expiration later this year, though the uncertainty over these extends to whether lawmakers have the funds available to make the provisions permanent or must simply prolong their expiration date by a few years. This brings us back to the uncertainty hanging over what should be a tax measure that leads to booming investment in the U.S. Due to the swelling size of the reconciliation package, and resistance from fiscally conservative Republicans in both the House and Senate, lawmakers are unlikely to have the fiscal room to make all tax provisions permanent. The battles in the halls of the Capitol are already being waged over which provisions to make permanent, which to extend, and which will fall by the wayside. These decisions are expected in the coming months as us tax lobbyists press full speed ahead. Aside from the tough tax decisions lawmakers face, the clock is ticking for another reason. The nation’s borrowing limit is fast approaching with the most generous of expectations being we will exceed our debt ceiling as late as September. Most here in Washington expect that if lawmakers cannot complete a tax bill by the August break, negotiations become more complicated. We feel confident that lawmakers will send a tax relief bill to President Trump this year. It will address the tax on R&D, provide incentives for capital investments, and possibly include a special rate or deduction for domestic manufacturing. The uncertainty surrounds whether Congress can make these incentives permanent, or are they simply a temporary reprieve. Placing heavy equipment into service can take years, and can cost millions more if shipped from overseas, even from an ally. The tariffs present an opportunity for tax policy and headwinds at the same time. In an ideal situation, Congress would make permanent all the tax provisions that structurally change why and how we manufacture in America. Combined with a stable and

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WASHINGTON UPDATE

strategic tariff strategy, manufacturers in virtually all sectors could flourish. Unfortunately, the questions over which tax incentives industry can rely upon and which tariffs will benefit their business will continue to linger well into the summer. As the President presses forward with his tariff strategy, most of those decisions will increasingly align in the coming months with the tax negotiations on Capitol Hill. As both issues converge, FIA members should look to the long term opportunities tariffs present, while planning their investments around potential short term tax relief. While my inbox is flooded today with tariffs, I do hope manufacturers do not lose sight of the tax relief, coming tomorrow.

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

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

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ENERGY

ENERGY PRICES RISING FAST: WHY A BIG UPWARD REVISION IS RAISING CONCERNS FOR 2026 By Nancy Gardner

I n March, the U.S. Energy Information Administration (EIA) released its latest Short Term Energy Outlook (STEO). From our perspective, the most interesting takeaways from the report are related to the natural gas market – in particular, how forecasts have changed over the past few months. In its October 2024 STEO, the EIA projected that Henry Hub natural gas prices would average $3.10 per MMBtu in 2025. The March report revised that number 35% (!) higher to $4.20 per MMBtu as shown in the chart below.

In addition to the depleted storage inventories, another factor influencing near-term prices is the development of two new LNG export terminals: Plaquemines LNG Phase 1 in Louisiana and Corpus Christi Stage 3 in Texas. These Gulf Coast export facilities have pushed U.S. LNG exports to record levels, at more than 16.7 Bcf per day. Over the next two years, we expect Plaquemines to nearly double its output to 4 Bcf per day and Golden Pass LNG in Texas to ship out another 2.5 Bcf per day. Canada also has large projects expected to come online in 2026. Depending on the impact of federal tariffs, our neighbors to the north could begin moving a majority of the 7 Bcf per day currently being sent into the U.S. via pipeline to more profitable markets overseas. Should all these projects progress as expected, the total amount of natural gas that is no longer available for domestic consumption will likely approach 10 Bcf per day – a major hole in available supply – by the end of next year.

A major reason for the upward adjustment is that below-normal temperatures in January and February led to increased natural gas consumption. This resulted in much more gas being drawn from storage than expected. U.S. inventories fell from a high of 3,972 Bcf in November to just 1,698 Bcf at the start of March. This 2,274 Bcf drawdown was 25% higher than the previous two winters. The STEO goes on to project that gas futures will average $4.50 per MMBtu in 2026. As of March 27th, the NYMEX calendar 2026 gas strip settled at $4.39, indicating that the agency expects prices to move even higher over the next year. Why Are Prices Moving Higher for 2026? Since July 2024, we’ve seen a steady upward trend in natural gas prices, however, most of the movement has occurred towards the front (i.e., the nearer years) of the forward curve. Calendar years 2027 and beyond have experienced much more modest changes: Trade Date Cal 2025 Cal 2026 Cal 2027 Cal 2028 Cal 2029 Cal 2030 07/29/2024 $3.24 $3.63 $3.71 $3.64 $3.59 $3.50

03/27/2025 $4.34 $4.39 $3.34 ∆ Change +34% +21% +4% -1% -3% -5% $3.87 $3.59 $3.47

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At the same time, U.S. gas production has stagnated. When natural gas prices reached rock bottom in the spring of 2024, production and exploration for gas decreased. Following eight consecutive years of steady growth, we’ve seen a decline in production over the past year:

While the fuel costs to generate electricity continue to rise, demand for power is also on an upward trajectory. New data centers are appearing across the country that host energy-intensive AI technology. There are serious concerns that load growth will substantially outpace the ability of supply to keep up over the next two years. Yes, we’ve heard news of large tech companies looking to rely more heavily on renewables or nuclear power, but wind and solar are intermittent resources and utility-scale nuclear power plants typically take 5-10 years to build with immense capital investment. What Is the Best Solution for My Business Moving Forward? The most prudent solution is to begin actively reducing medium to-long term exposure to price risk. As summer approaches, there will be increasing fears of growing energy consumption nationally – and with them price pressures – based on cooling needs. And continued LNG export growth is likely to cause shortage concerns and more volatile prices. At Transparent Energy we recognize the dangers of scarcity risk premiums finding their way into the wholesale energy markets, and the impact it could have on our client’s bottom lines. We do not see any meaningful relief for prices in 2025 or 2026, and the opportunity to lock in rates for 2027 and beyond is unlikely to get much more attractive than where those strips are trading today. Now is the time to act. If you are concerned about rising energy prices and their impact on your business, contact our Transparent Energy energy procurement expert today ngardner@transparentedge.com. Nancy Gardner Transparent Energy Email: ngardner@transparentedge.com Phone: 732-288-5126

The EIA is forecasting the return of production growth over the next two years; however, the increase pales in comparison to the expected rise in exports. Natural gas production companies have made it clear that they are only willing to pull more gas out of the ground when prices meet their acceptable level. What is acceptable? A recent survey of energy companies suggested that the average price needed to incentivize new natural gas drilling was $4.66 per MMBtu – again, higher than today’s prices. Ok, So Natural Gas Prices are Moving Higher, Does This Affect My Electric Bill as Well? YES! Electricity prices across the country are driven by the cost of natural gas.

Source: EIA There is a >90% correlation between the price of natural gas and electricity rates across ERCOT, PJM, MISO, NYISO, and ISO-NE, and natural gas consumption in the power generation sector has never been higher.

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EQUIPMENT & TECHNOLOGY

MINIMIZE DELAYS & MAXIMIZE SAVINGS WITH TURNKEY FORGING LINES By Jaime Israel

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.

L ightweight construction is a rapidly increasing need for the automotive market, especially for alternative powertrains that require better mileage and fatigue life strength of parts. As forgers predominantly produce solutions for the automotive market, it is more imperative than ever to source cost-effective solutions that increase capacity and efficiency of production lines. The solution: highly automated, turnkey forging lines—applicable for both aluminum and steel—from a one-stop, one-source supplier.

What Does Turnkey Include? • Forging Press(es) • Automation & Seamless Integration (e.g., Robots, Transfer Systems, Mono Beams, etc.) • Service Support

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EQUIPMENT & TECHNOLOGY

Choosing The Best Automation For Your Forge Shop Forgers win competitive projects, whether using hammers, crank presses, or screw presses, based on their production flexibility and economical solutions for producing a wide variety of parts. Automation contributes greatly here as the technology improves process stability and increases output rates. There are many different automation systems that forgers can choose, such as commercial standard robots, hanging robots with additional linear moving axes on suspension frames, mono beams, and walking beam transfer systems. • Robot Automation: These systems, while less expensive, can have limitations when considering higher output rates. • Mono Beam / Walking Beam Systems: These technologies are much faster and more precise than robot automation— and are often associated with automated crank presses, as well as recent adaptations for screw presses. • The ANDRITZ Schuler Tri-Axis Servo Transfer: This transfer system provides the maximum, and most reliable, positioning accuracy. The basis of the Tri-Axis Servo Transfer is electrical- and servo motor-driven. Optimized forming, motion spray, and cooling processes can be achieved if the transfer system is combined with a servo press drive. All grippers are equipped with quick disconnect coupling systems for fast replacement without any long production downtimes. Keep It Simple: One Supplier, Complete Solutions Working with one supplier for a complete turnkey solution will save forgers both time and money as a one-source supplier eliminates tedious back-and-forth, project delays, and extensive supplier onboarding protocol. ANDRITZ Schuler, as an example, offers customizable solutions for all requirements of forging and automation solutions that are designed for cold, warm, and hot forging.

Achieve up to 30 strokes/min and produce higher quality parts with ANDRITZ Farina's KERS system's advantageous conventional and servo drive.

DO FORGERS REALLY NEED TURNKEY FORGING LINES? Yes, but one must first fully understand the forging process required for the demands of the automotive industry—particularly for aluminum material that involves forging, machining, assembling, and the development, construction, and design of chassis parts. • The process begins with a billet. • The billet is transferred to a pre-heating furnace to be heated at the required forging temperature. • The billet is picked up by a loading robot from the furnace conveyor and placed on the hydraulic press (if required) for the pre-bending of the component. • The pre-formed component is then placed onto the first station of the multi-station press (i.e., mechanical, hydraulic, or screw presses). • The forged part needs to be transferred for heat treatment (the final step). • Automation is determined—e.g., robot transfer, mono beam transfer, or twin transfer—by the specified volumes, part geometry, and cycle time. • The full turnkey forging line is also designed for the specific heat treatment of the desired part. This is a simplified overview of the forging process; the process can be tailored for specific forging project needs.

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EQUIPMENT & TECHNOLOGY

ANDRITZ Schuler’s product portfolio includes mechanical and hydraulic presses, screw presses with direct drive, and forging hammers. All presses are available in series with small to large tonnages. Mechanical systems, like ANDRITZ Farina’s KERS system (kinetic energy recovery system), can provide forgers with the advantage of a conventional and servo drive, electrical energy savings, and higher quality part production with up to 30 strokes per minute. KERS installed on the GLK press, as one example, reduces power consumption by up to 40% with increased output; this machine can be installed as a part of a fully automated line, that includes several robots and ovens, or as another press in the line for trimming the flash of forgings. The operators’ only task would be monitoring production. Forging lines with the drive concepts mentioned are in operation worldwide. One case study includes the GLK 2,500-ton turnkey line for the production of aluminum suspension parts. This completely automated line is currently in operation for the powertrain and battery housing industries. Beyond technology, automation, and digital solutions for a fully networked forge shop, ANDRITZ Schuler provides process expertise and service made for you. Visit ANDRITZ and ANDRITZ Schuler at Forge Fair, booth 708. Forgers can learn more about turnkey solutions and ANDRITZ Schuler technology at the following Forge Fair presentations: “Efficient Ring Rolling with Digital Products” (May 13, 2:45 PM, Room E) and “Efficient Aluminum Forging: From Concept to Completion” (May 14, 2:45 PM, Room A). 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. Jaime Israel Director, Marketing & Communications ANDRITZ Schuler Incorporated Phone: 734-865-0133 Email: : Jaime.Israel@andritz.com

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EQUIPMENT & TECHNOLOGY

THE BENEFITS OF OEM REBUILDS AND UPDATES FOR HYDRAULIC & MECHANICAL FORGING EQUIPMENT By Jared Green

W hen it comes to maintenance of any sort, I think back to a line I read in Hot Rod Magazine: “If everything I owned worked, I’d be bored”. All equipment no matter what it is or who built it will eventually require parts and service. Even well-maintained equipment will eventually wear out and require a rebuild or an update. Nothing Beats Original Parts It’s often said that nothing beats original parts. And I think anyone that works on classic cars or older equipment is all too familiar with this. We’ve all been disappointed at some point with shoddy replacement parts for your car or your equipment. But when you can source the OE replacement parts, they drop right into place without having to make any added modifications, and they last longer.

running without the appropriate documentation, future orders for replacement parts that are made to fit can be challenging. If drawings are incorrect, the wrong parts may be ordered, causing production delays. And reverse engineered parts, while they may work to an extent, are often based on worn out parts. At a previous job, I worked on gears and rotating components. And in a particular application we used lead correction on a gear to account for shaft deflection under load. This modification was undetectable without the use of specialized measurement equipment, and undetectable at the time a rebuild was needed. Third party rebuild shops that copied and/or reverse engineered the gearing would miss the lead correction which ultimately led to a shorter gearbox life and premature failure. Details like this are easily missed (or neglected) by most aftermarket shops. Sometimes thousandths of an inch make all the difference. Controls and Automation Equally as important to the mechanical and structural components are the electronics and controls. With constant updates being made to electronic components, older components get phased out and become increasingly harder to source. New electronic components also have improved safety and diagnostic capabilities. Legally, OE suppliers are required to update control and automation systems to the latest safety standards. While this may seem like undue burden, safety is something that should be taken very seriously from a legal and a preservation of health and life standpoint. For example, starting on the outside of the cabinet is a voltage vision and voltage portal feature. Indicating the presence and the ability to test power without opening the cabinet. Also, on the exterior of the cabinet is the SCCR rating, based on a thorough component study. Inside the cabinet, Class J & L fuses are used to reduce arc flash radius, as well as dual cycle start pushbuttons to prevent inadvertent machine motions. These are just a few of the many updates that make OE controls rebuilds safer. With more advanced controls comes the option for more automation. And with staffing and workforce shortages, more and more forgers are moving to fully automated cells. With updated and more advanced controls, cells can be programmed for synchronized part picking, furnaces, conveyors, billet loaders, die spray, robot transfers and exit conveyors much more efficiently.

While you may not be able to source factory parts for all your equipment, many OE forging machine suppliers have all the original drawings, and even the service records of the equipment. This makes the difference when you want to be able to bring your machine back to OE tolerances. Parts that need to be repaired, modified or replaced have new drawings made and stored for record. This documentation and record keeping makes future replacement part orders more predictable. With accurate drawings, engineers can more readily support customers should problems arise. Aftermarket parts that are reverse engineered or “made to fit” can miss important details. While they may get a machine up and

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EQUIPMENT & TECHNOLOGY

Further improving efficiency is the use of VFD motor controls. With the use of VFD motor controls, hydraulic pump motors can be slowed or idled when not in use. Idling the motors avoids the inrush current from stopping and starting the motors. Idling the motors also reduces noise, pump wear and cooling requirements. When VFD controlled motors are used in combination with “smart” variable displacement pumps, press velocity and control functions are more efficient than resistive throttling. Mechanical presses can also benefit from the use of VFD controlled motors. With NEMA C&D motors being increasingly difficult to source, VFD can be used to modify the torque curves of off the shelf motors. This allows for better speed control of mechanical presses. The ANSI Code requires all new control systems to have "Control reliability." This refers to the design and implementation of safety related control systems to consistently perform their intended safety functions, even in the presence of specific faults or failures. Key Aspects of Control Reliability: 1. Fault Tolerance: The system must detect and respond to faults (e.g., wiring issues, component failures) without losing its ability to protect operators or equipment. 2. Redundancy: Critical components are often duplicated so that the other can maintain the safety function if one fails. 3. Monitoring: The system must continuously monitor itself to detect failures and take the appropriate action (e.g., stopping a machine if a safety function can't be guaranteed). 4. Fail-Safe Operation: In the event of a failure, the system defaults to a safe state (e.g., shutting down machinery). For Example: In a machine with a safety gate, control reliability ensures that if a contactor fails or a wire breaks, the machine will still stop when the gate is opened, maintaining operator safety.

Hydraulics Significant advances have been made in hydraulic components and controls. While some components can be rebuilt, older components are phased out. While OE rebuilt components can restore a machine to its original operating standard, modern controls can enhance the performance of older equipment. OE hydraulic equipment is also engineered and sized to meet specific customer requirements. Hydraulic systems are designed to optimize performance and minimize heat and pressure spikes. Hydraulic schematics are documented to assist with machine function and system diagnostics. Modern hydraulics are also smarter, communicating with the control system to provide an active schematic on the operator’s screen, providing real time pressure, temperature and position feedback for easier diagnosis. Adjacent to hydraulics, OE lubrication systems are engineered per specific application. Lubrication systems are designed to apply only as much lubrication as needed, based on effective area, velocity, and load. Because the system is properly sized abrasive wear is reduced, and less lubrication is wasted. In one application oil (or grease) consumption was cut in half with no adverse effects to the equipment. When rebuilding, updating, or re-rating forging equipment in particular, OE support isn’t a luxury, it is a strategic advantage. With original specifications, updated technologies, and a deep understanding of the equipment, OE provides peace of mind and performance you can count on. Jared Green, Sales Application Engineer with Ajax/CECO/Erie Press.

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EQUIPMENT & TECHNOLOGY

PUSHING THE LIMITS OF FORGING: Technical Advancements in Lubricant Engineering By Frank Sobnosky

A s forging operations evolve to and extreme forming environments, lubrication remains a critical variable in process efficiency, die life, and part quality. Recent developments in modifying lubricant tribology—the science of friction, wear, and lubrication—are reshaping how the industry approaches lubricant selection, accommodate increasingly complex geometries, aggressive cycle times, In forging, lubrication is far more than an ancillary consideration. It directly affects metal flow, life, energy consumption, and surface finish. A nuanced understanding of tribological principles is essential, particularly as die temperatures rise, cycle times shorten, and the demand for dimensional consistency and production volume intensifies. Forging lubricants today must serve multiple functions: reduce die-workpiece friction, dissipate heat, prevent part sticking in the die, enable proper metal flow, and do so while minimizing environmental impact and operational downtime. Modern Lubricant Classes and Their Applications While there are several types of forging lubricants used for various purposes today, the main classes of lubricants will be discussed in this article. The choice of class is key for each forging operation, however, what may be even more important is tailoring each product to specific operational needs and forming conditions. The Stribeck Curve (figure 1) governs the tribological interactions between the tooling and workpiece. Each category discussed in this article relates directly to a formulation, and application. Lubrication as a Strategic Engineering Variable

lubrication regime in the Stribeck Curve. A properly controlled coefficient of friction is the ultimate goal of forging lubrication, not the lowest possible coefficient of friction. Too little friction between the tool and workpiece can lead to metal overflow and improperly formed parts. Choosing an optimized lubricant which the correct lubrication regime leads directly to successful forging. Graphite in Water A widely used boundary lubricant, graphite-in-water systems utilize graphite as the functional material and water as the carrier. Organic binders ensure adhesion to hot die surfaces, creating a protective film that enables clean separation between the tool and workpiece. Water simply exists in these lubricants to deliver the graphite and binders to the die surface, where they create a boundary film to lubricate and part the tooling and workpiece. This is the right-most category on the Stribeck Curve (boundary lubrication), also called “dry film lubrication”. The coefficient of friction between the tool and the workpiece is higher than a hydrodynamic lubricant. This is needed to control metalflow and provide just enough lubricity to flow metal to the end of the impression. Recent innovations in dispersion techniques have improved the performance of these graphite dispersions. Properly controlled graphite particle sizing and graphite type choice, as well as optimized dispersion techniques have contributed to these improvements significantly. These enhancements have extended metal flow performance in deep-draw and extrusion operations, improved die protection, and reduced total lubricant consumption. Additionally, soft-film formulations have been developed that provide excellent die coverage with minimal overspray,

improving cleanliness and reducing interference with automation systems. Graphite in Oil and Emulsions Graphite in oil-based systems remain indispensable for high-temperature, long metalflow forging, especially with non-ferrous materials and aerospace components. These lubricants perform well above 600°F, where water-based carriers fail due to the Leidenfrost effect. Oil not only serves as a carrier but also contributes to lubrication itself. These lubricants operate under both the hydrodynamic and boundary regimes. The oil carrier not only delivers graphite to the die surface but also provides hydrodynamic lubrication to lower the coefficient of friction. The graphite serves as a boundary lubricant in a comparable manner to graphite in water products. The combination of these regimes in both graphite in oil and emulsion lubricants. Hybrid emulsion systems—where oil is emulsified and graphite is dispersed in water—balance thermal insulation and cooling. These are particularly effective in overcoming steam barriers at elevated temperatures when properly engineered. Advances in graphite particle sizing control, wetting agents, and film formation technologies have made these systems viable for more extreme applications with reduced environmental trade-offs compared to pure oil-based formulations. Synthetic (Salt-Based) Lubricants Salt-based synthetic lubricants are created through acid-base reactions and are primarily used in warm forming. While they offer limited metal flow support, they excel in die cooling and minimizing sticking. This makes them ideal for forming components like pinions, yokes, and joints where localized

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lubrication and plant cleanliness are essential. These lubricants offer partial “Elastohydrodynamic” lubrication (middle section of the Stribeck Curve” and also part the tooling and workpiece surfaces Engineering Lubricant Performance: The Multivariable Equation Lubricant selection is a multivariate optimization problem that involves: • Forming and Die Temperatures: High-temperature processes (>2000°F) require different lubrication strategies than warm forming (<2000°F). Die temperature also governs wetting behavior—water based systems lose effectiveness above 550°F unless chemically enhanced. • Metal Flow Severity: Complex operations such as extrusion, severe lateral flow, or deep drawing demand lubricants with superior adhesion and flow-extension properties. • Press Characteristics and Production Volume: Whether mechanical, hydraulic, or hammer, the type of press affects forging conditions and lube film behavior. High-volume applications with tight cycle times demand robust and consistent lubricant performance. • Application Method: Spray, dip, swab, and flood methods all require different viscosities, atomization characteristics, and thermal properties from the lubricant. Matching these parameters with the correct, optimized lubricant formulation directly impacts consistency, tooling longevity, and throughput. Advancements in Film Engineering and Tribological Control Soft-film graphite lubricants are among the most significant recent breakthroughs. These films, in the right processes, maintain the protective qualities of traditional hard films but with improved sprayability, adhesion, and cleanability. However, there are specific applications

which require thicker, hard films for optimized performance and enhanced metalflow. Soft films also eliminate common issues such as electrical interference from graphite overspray, reduce machine downtime, and enable more precise lubricant targeting. In emulsion systems, wetting at elevated temperatures has historically been a barrier due to the Leidenfrost effect. Advanced formulations now include additives that break the steam barrier, enabling consistent wetting above 550°F. This development is critical in isothermal forging of non-ferrous alloys, where uniform lubrication is essential. Additionally, newly engineered EP (extreme pressure) additives and friction modifiers have improved boundary lubrication properties, lowered required tonnage, and expanded

mechanical, and geometric demands. Advances in formulation, film science, and application methodologies have made it possible to improve metal flow, reduce friction, extend tool life, and ensure consistent part quality across a wide range of forging environments. As the forging industry continues to pursue higher performance and operational efficiency, the integration of modern tribological science into lubricant design and use will remain essential. Further discussion of these topics and more will occur at Forge Fair in Cleveland, OH on Wednesday May 14th at 10:50am. AML will present Forging Lubricants: Advancements in Tribology and Applications for Optimal Performance. Please join us for an informative discussion of these topics in further detail.

metal flow without increasing material resistance. These improvements reduce stress and extend tool life in demanding conditions. Application and Handling: The Often-Overlooked Variable Even the most advanced lubricant formulations will fail if not properly applied. Atomized spray

Figure 1: Stribeck Curve

application remains the most effective method for water-based lubricants at die temperatures up to 550°F. Key factors for application include spray pattern, sprayed droplet size, spray pressure, spray angle, and others. On the handling side, proper agitation is critical—particularly for graphite-containing systems. Factors such as blade choice, blade positioning, mixer RPM’s, and numerous other variables are key to lubricant handling success. Conclusion Forging lubricants are no longer one-size fits-all solutions but highly engineered components that must be precisely matched to each operation's thermal,

Frank Sobnosky Jr. Chemical Engineer AML Industries, Inc Phone: 330-399-5000 Email: fsobnosky@amlube.com www.amlube.com

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THE ELEPHANT IN THE ROOM – WHAT DOES INDUSTRY 4.0 REALLY MEAN IN THE FORGING INDUSTRY? By Michael Hoffmann, Tim Lehnert, Jan Müller and Carola Sekreter

I ndustry 4.0, often described as the “Fourth Industrial Revolution” represents a fundamental change in manufacturing driven by digital innovation. It is described as the integration of physical production processes with digital technologies such as the Internet of Things (IoT), big data analytics, and AI. This convergence results in “SMART factories” where systems communicate autonomously, and data flows freely across the production landscape. Sounds ingenious – and complicated.

tooling, lubrication with their own subsequent variances, and nonconformities that directly influence product quality and cost. Industry 4.0 takes this time-tested manufacturing process to a new level of efficiency and precision. It targets enhanced process monitoring and establishes defined codependence between operations to recognize and mitigate non-conformances. Integrated AI predicts long-term trends and potential risk of non-conformity. This greatly improves control of the manufacturing operations, increases competitiveness, reduces downtime and cost.

In recent years, Europe has become synonymous with digital transformation in manufacturing while adaptation to Industry 4.0 in the U.S. has been rather slow. Europe’s success in this realm is evident in how manufacturers have embedded technologies like inline quality monitoring and hot part measurement directly into their production lines. These technologies have elevated product quality and paved the way for greater efficiency in supply chains and production workflows. European institutions, particularly the Germany-based Fraunhofer Society, have played a critical role in bridging the gap between research and industrial application, to ensure that groundbreaking technologies quickly transition from the lab to real

Figure 1: Linked data in manufacturing organization.

world production environments. Italy-based FICEP, one of the world’s leading press manufacturers, has integrated Industry 4.0 technologies within their products. From advanced sensors, real-time data analytics and artificial intelligence (AI), to interconnected cyber-physical systems, these innovations have set benchmarks in forge product quality, Adopting digital tools in forging and forming processes vastly enhances quality, efficiency, and competitiveness. This process already begins at the component development stage. Using simulation-based component design, forged parts can be developed and engineered to suit manufacturing requirements, ensuring optimal die filling during forming and minimizing tool wear through an optimized sequence of forming stages. What’s more, continuous process simulation enables the prediction production efficiency, and operational agility. Let’s look at some of these digital technologies.

What Does Industry 4.0 Look Like in a Forge Shop? Many of us in the forging industry are familiar with traceability requirements, pyrometers, vision cameras, and tonnage monitors. But does that count as Industry 4.0? And at what point is a forge shop considered a SMART Factory? These are important questions to answer when evaluating your current production and future growth. Industry veterans often refer to the forging process as, “The Art of Heat It & Beat It.” Technically speaking, this means that a billet is shaped largely via compressive loading into a desired state. To transform the billet into a forged product, several operations are needed such as shearing or saw cutting, billet preparation, heating, preforming or bending, forging, trimming, cooling or heat treatment. All these operations exhibit subsystems such as

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of part properties. Based on these results, components can be geometrically optimized in reverse under given boundary conditions. The following image illustrates such a development sequence.

Figure 4: Live view press load monitor system identifying overloads of mechanical presses, developed at Fraunhofer IWU. At the core of these advancements is the ability to collect and analyze data across the entire production process. Centralized data hubs gather input from a variety of sources, including machines, tools, an ERP system, and the human within the process chain. In concert, these elements facilitate a comprehensive digital overview. Applying statistical tools to the collected data to create a visual job performance or machine downtime analysis, are widely used approaches. To illustrate some of the applications, we will use an exaggerated example of tonnage values for three different forging processes over their past several production runs. The graph below shows a box plot of average tonnage measured for three different parts over their last six production runs. Cluster 1 shows that one setup with subsequent production resulted in an average max tonnage of 34 tons for this specific run. The lowest average tonnage of eight tons was measured for another production lot. The median tonnage of all six runs lies at 23 tons. The statistical 75% percentile lands at 27 tons and the 25% percentile lies at 15 tons.

Figure 2: Optimized production with digital tools. Let’s look at inline quality monitoring systems as an example. This effective monitoring system can continuously inspect production in real time, promptly detecting defects and allowing for immediate adjustments. This not only reduces waste but also ensures that every component adheres to rigorous quality standards.

Figure 3: XEIDANA - Multi sensor inline quality inspection system by Fraunhofer IWU, Germany. Hot part measurement technologies offer another significant advantage, by providing accurate dimensional data on components that are still at elevated temperatures. This capability is particularly crucial in forging, where rapid and precise measurements help to predict proper part quality. Press load monitoring is a domain where digital innovation can make a profound impact. By installing sensors on mechanical presses, manufacturers can continuously track operating loads. This real-time data supports predictive maintenance strategies, allowing potential issues to be identified and addressed before they result in unplanned downtime. The overall effect is a smoother production cycle, longer equipment life, and better resource utilization.

Figure 5: Press tonnage data for three different products over six production runs. Cluster 1 shows the largest variation amongst the three different forged parts. Widespread tonnage variation in forging operations, among other things, can indicate setup variation, (e.g., ram adjustment too far down or the billet weight varies too much

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