Forged Flange Definition:

A forged flange is a type of flange that is manufactured through a forging process. It is a component used in piping systems to connect pipes, valves, or equipment, providing a secure and leak-proof joint.

Forged Flange Production Method:

Forged flanges are produced through the forging process, which involves shaping metal by applying compressive forces. In this method, a solid piece of metal, typically a round bar or billet, is heated and then shaped using high-pressure equipment, such as a hammer or press. The metal is deformed and shaped into the desired flange form, ensuring superior strength and durability.

Forged Flange Processing Steps:

The production of forged flanges typically involves the following steps:

1. Raw Material Preparation: High-quality raw materials, such as carbon steel, stainless steel, or alloy steel, are selected based on the specific requirements of the application.

2. Heating: The raw material is heated to a suitable temperature to make it malleable for forging. The heating process may involve furnaces or induction heating.

3. Forging: The heated metal is shaped using a forging hammer or press. It is subjected to controlled and precise impacts or pressure to deform it into the desired flange shape.

4. Trimming and Finishing: The forged flange is trimmed to remove excess material and achieve the desired dimensions. It undergoes machining operations such as milling or turning to refine the surface finish.

5. Heat Treatment: To enhance the mechanical properties and achieve the desired hardness, the forged flange may undergo heat treatment processes such as quenching and tempering.

6. Testing and Inspection: The forged flange undergoes various tests and inspections to ensure its quality, including dimensional checks, visual inspections, and non-destructive testing methods such as ultrasonic testing or magnetic particle inspection.

Forged Flange Classification:

Forged flanges can be classified based on different criteria, including:

1. Facing Type: Forged flanges can have different facing types, such as raised face (RF), flat face (FF), or ring type joint (RTJ).

2. Pressure Class: They are classified based on pressure ratings, such as Class 150, Class 300, Class 600, etc., indicating their maximum allowable pressure.

3. Flange Type: Forged flanges can be classified into various types, including weld neck, slip-on, socket weld, threaded, blind, or lap joint flanges, among others. Each type has specific characteristics and applications.

Forged Flanges Manufacture Standards

1. ASME B16.5: This standard, published by the American Society of Mechanical Engineers (ASME), provides specifications for pipe flanges and flanged fittings in sizes ranging from ½ inch to 24 inches. It covers dimensions, tolerances, materials, pressure ratings, and facing types for forged flanges.

2. ASME B16.47: Also published by ASME, this standard covers large diameter steel flanges (NPS 26 through NPS 60) for high-pressure applications. It includes two series: Series A (MSS SP-44) and Series B (API 605), each with different dimensions and ratings.

3. EN 1092-1: This European standard specifies the requirements for circular flanges for pipes, valves, fittings, and accessories. It covers a wide range of sizes and pressure ratings and provides various flange types, such as weld neck, slip-on, and blind flanges.

4. DIN 2631-2638: These standards, published by the German Institute for Standardization (Deutsches Institut für Normung), cover weld neck and slip-on flanges for use with PN-designated flange connections. They specify dimensions, materials, pressure ratings, and facing types.

5. JIS B2220: This Japanese Industrial Standard covers steel pipe flanges for nominal sizes from 10A to 1500A. It provides specifications for dimensions, materials, pressure ratings, and facing types for forged flanges used in Japan and other regions that adopt JIS standards.

6. GB/T 9112-2010: This Chinese national standard defines the dimensions, materials, pressure ratings, and facing types for carbon steel and low-alloy steel pipe flanges. It covers a wide range of sizes and is widely used in China.

Forged Flange Test:

Forged flanges undergo rigorous testing to ensure their quality, reliability, and performance. Some common tests performed on forged flanges include:

1. Dimensional Inspection: This involves checking the flange dimensions, including diameter, thickness, height, and hole alignment, to ensure they meet the specified requirements.

2. Visual Inspection: A visual examination is conducted to detect any visible defects, such as cracks, surface imperfections, or irregularities.

3. Non-Destructive Testing (NDT): NDT methods like ultrasonic testing, magnetic particle inspection, or liquid penetrant testing are employed to identify any internal or surface defects that may affect the flanges integrity.

4. Mechanical Testing: Tensile testing, hardness testing, and impact testing are performed to evaluate the mechanical properties, including strength and toughness.

5. Pressure Testing: Forged flanges may undergo hydrostatic or pneumatic pressure testing to verify their ability to withstand the specified pressure without leakage.

These tests ensure that forged flanges meet the required standards and performance criteria, making them reliable and suitable for their intended applications.

Forged Flange, Forging Flanges