Bringing It Back Home: Exploring the Advantages of Reshoring

Posted on July 6, 2023July 6, 2023 by lsmith

Bringing It Back Home: Exploring the Advantages of Reshoring

As the global economy continues to evolve, reshoring has become an increasingly popular topic among businesses of all sizes. Reshoring refers to the practice of bringing manufacturing and other business operations back to one's home country, rather than outsourcing them to other countries.

The history of offshoring

Off-shoring refers to the practice of a company relocating its business operations to another country where labor or raw materials are cheaper. The concept of offshoring and outsourcing has been around for centuries, but it became popular in the late 20th century.

In the 1960s, global trade began to increase, and companies started to explore the option of offshoring to reduce labor costs from international manufacturers.

In the 1980s, advances in technology and transportation made it easier for companies to communicate and transport goods across borders, further fueling offshoring growth.

In the 1990s, the North American Free Trade Agreement (NAFTA) and the General Agreement on Tariffs and Trade (GATT) were signed, which made it easier for companies to do business across borders.

In the 2000s, China emerged as a major player in the global economy, and many companies began to offshore their manufacturing jobs to take advantage of China's low labor costs. Off-shoring was a common practice for many industries, including manufacturing, IT, and customer service.

The global pandemic in 2020 resulted in significant supply chain disruptions, leading to a major shift in offshoring operations. The importance of companies having solid domestic sources became increasingly evident.

Additionally, while it can be controversial due to concerns over job loss and exploitation of workers in developing countries, it remains a strategy for companies trying to reduce costs and increase profits.

Reasons for offshoring

Companies offshore to take advantage of lower labor costs, access to new markets, and favorable tax policies. Offshoring also helped companies increase efficiency, reduce costs, and access specialized skills and technology.

Offshoring allows companies to benefit from lower labor and operational costs in other countries. Offshoring can provide companies with time zone advantages, allowing them to operate around the clock and be more responsive to customer needs. Offshoring can provide companies with a competitive advantage by allowing them to offer products or services at a lower initial cost.

However, offshoring can also have some drawbacks, such as language and cultural barriers, legal and regulatory issues, lower quality standards, and the potential for negative public perception. Not to be overlooked is the unstable and unpredictable political climate in some countries that could cause an unexpected stoppage in the ability to get product.

The Advantages of Domestic Manufacturing

Domestic manufacturing, or producing goods within one's own country, has numerous advantages. Domestic manufacturing can lead to improved quality control, faster turnaround times, and cost savings among numerous other benefits.

Improved quality control: When operations are located closer to home, it's easier to monitor quality and ensure that products meet high standards. This can lead to increased customer satisfaction and loyalty, and a decrease in defective products. When innovation is necessary, having a supplier that is close in proximity will enable greater innovation and improve product quality. When production is closer to home, companies have more opportunities to experiment with new materials, designs, and techniques, while still maintaining quality management.
Faster turnaround times: With operations located closer to home, businesses can respond more quickly to changes in demand and adjust their production schedules accordingly. Language barriers can reduce turnaround time - communicating in real time can expedite the production process. This can help them stay competitive in a fast-paced market.
Cost savings: While outsourcing to other countries can seem like a cost-effective solution at first, the hidden costs of transportation, communication, and quality control can quickly add up. Reshoring can help businesses reduce these costs and improve their bottom line. For example, if a product requires a lot of customization or has a high degree of complexity, it may be easier and more efficient to produce it locally.
Environmental impacts: Domestic manufacturing reduces transportation costs and carbon emissions. This is because goods are produced closer to where they will be sold, reducing the need for long-distance transportation. The US has some of the highest environmental standards for the industry in the world, while some countries may have very few if any standards.
Boosting the economy: Purchasing domestically will revitalize the local economy. Not only does it create job opportunities, but it also promotes economic growth. This can help reduce unemployment and poverty, ultimately lessening the need for government assistance.
National security: Finally, domestic manufacturing can lead to greater national security. This is because countries that are self-sufficient in the production of essential goods are less dependent on other countries in times of crisis.

Overall, the benefits of domestic manufacturing are clear. Reshoring offers a number of advantages for businesses that are looking to stay competitive in today's rapidly changing market By creating jobs, reducing transportation costs and carbon emissions, ensuring higher-quality products, and promoting national security. Given the benefits of domestic manufacturing, it's no surprise that many countries are putting more emphasis on it.

Forgings Made Domestically

Off-shoring's rising popularity dealt a blow to the forging industry. In the past, US-based forging companies struggled to meet the needs of customers who demanded high-volume forged components at a competitive global price. This was a result of offshoring becoming more prevalent.

Manufacturers based in the United States face considerable risks due to extended overseas lead times and the current political climate. With long lead times and supply chain uncertainties from international suppliers, the risk of material shortages looms large and impacts manufacturing capabilities.

Manufacturers will greatly benefit from a domestic supplier for their forged components for the many reasons stated above. In addition to those benefits Southwest Steel's steel supplier is right next door and is integrated with the manufacturing process, therefore the lead times for steel are short, and our capacity for manufacturing is shortened with available raw materials. This enables SSP to compete with globally competitive pricing – as we maintain the lowest cost industry steel pricing with no transportation costs and improve quality control in manufacturing processes.

Manufacturers can reap numerous benefits from using a domestic supplier for their forged components, as previously mentioned. In addition, Southwest Steel Processing's steel supplier is fully integrated with the manufacturing process, resulting in shorter lead times for steel and increased manufacturing capacity due to readily available raw materials. This allows SSP to compete with globally competitive pricing, maintaining the lowest cost of steel in the industry, with no transportation costs.

Discover how our large railcar manufacturer client benefited from domestic forged parts sourcing. Read our case story.

To learn more about our USA-made forgings or to request a quote, get in touch with our sales team today.

Unlocking the Strength: The Importance of Heat Treating

Posted on July 5, 2023July 5, 2023 by lsmith

Heat treatment is a specialized process that involves precisely controlled heating and cooling of metals and metal alloys to modify their crystalline structures. This process is widely used in metal fabrication to enhance the hardness, temperature resistance, ductility, and overall strength of materials.

Here are some key points to keep in mind as you delve into the world of heat treatment:

Heat treatment can be used to improve the strength, hardness, and durability of materials.

Different materials require different heat treatment techniques. For example, annealing is used to soften metals, while quenching is used to harden them.

Heat treatment can also be used to alter the electrical and magnetic properties of materials, making it an important process in the manufacturing of electronic devices.

Understanding the science behind heat treatment is essential for achieving consistent results and avoiding defects in the final product.

With the right equipment and expertise, heat treatment can be used to produce materials with highly specific properties, making it a powerful tool in the hands of skilled engineers and scientists.

One of the benefits of heat treatments is that it does not change the shape of the product, making it an essential aspect of metal fabrication processes.

Different Methods of Heat Treatment

Heat treating is a critical process in the manufacturing industry. It involves heating and cooling materials to alter their physical and mechanical properties. This process can make the material more durable, strong, and resistant to wear and tear. Here are some heat treating techniques that you should know about to unlock the power of heat.

Annealing: The annealing process involves heating a material to a specific temperature and then allowing it to cool at a gradual rate. The goal is to relieve any internal stresses and make the material more ductile.
Tempering: After hardening the material, the tempering process is done to improve toughness and reduce brittleness. This technique involves heating the material to a specific temperature and then cooling it in air or oil.
Quenching: This technique involves heating the material to a specific critical temperature and then cooling it rapidly. The goal is to harden the material and make it more resistant to wear and tear.
Normalizing: This technique is similar to annealing, but the cooling process is faster. The goal is to make the material stronger and more ductile.

Stages of Heat Treatment

Heat treatment is a process used to alter the mechanical and physical properties of materials, such as metals and alloys. Understanding the various stages of the heat treatment process is crucial to achieving the desired results.

Overall, understanding the stages of heat treatment and how they affect materials, depending on the type, is essential for anyone working with metals and alloys.

Here are stages involved in heat treatment:

Heating: This is the initial stage of heat treatment. The temperature is determined by the material being treated and the desired outcome. For example, heating a metal to a high temperature can make it easier to work with, while heating it to a lower temperature can increase its strength.
Soaking: Once the material has reached the desired temperature, it needs to be held at that temperature for a specific period of time. This is known as soaking, and it allows the material to reach a uniform temperature throughout.
Cooling: Once the material has been soaked, it needs to be cooled down. There are different cooling methods, including air cooling, oil quenching, and water quenching. The cooling rate and method used depends on the material being treated and the desired outcome. The rate of cooling can affect the final properties of the material, so it is important to control this carefully.
Tempering: This is an optional stage that is sometimes used to improve the toughness of the material. The material is heated to a lower temperature than in the initial heating stage and then cooled down again.

Overall, understanding the stages of heat treatment is crucial in ensuring that the material being treated is transformed in the desired way.

Internal Heat Treatment Capabilities for Your Forged Components

We're proud to offer in-house heat treatment capabilities to transform your forged components accurately and efficiently so that they meet the mechanical and physical requirements of your specific industry or application.

This will save you time and money by eliminating the need for an additional supplier to handle heat treatment. Our services include normalization, quenching and tempering, annealing, and induction hardening.

Our team is highly skilled and equipped with state-of-the-art technology to provide precision heat-treating services for your components.

To find out more about or high-volume forging capabilities contact us today to talk to our experienced sales team.

Posted on May 26, 2023May 30, 2023 by lsmith

Benefits and Applications of Induction Hardening Technology

The concept of induction heating has been utilized in manufacturing since the 1920s. Nowadays, precisely controlled induction heating systems play a crucial role in the manufacturing industry. Induction heating helps expedite part production, ensures consistent high-quality results, and reduces overall costs.

Induction hardening is a type of surface hardening process that is commonly used to increase the hardness and durability of various types of metal components. The process involves heating the surface of the metal using an induction coil, which generates a high-frequency electromagnetic field. This causes the surface of the metal to heat up rapidly, while the core remains relatively cool resulting in a martensitic transformation.

The benefits of induction hardening include:

- Induction hardening is a rapid heating process that uses high-frequency electricity to heat the surface of a metal part to a temperature above its transformation point. This results in the formation of a thin, case hardening with a tough and ductile core.
- The process can be used on a wide range of ferrous and non-ferrous materials, including steel, cast iron, brass, and aluminum.
- The increased hardness and wear resistance of the hardened surface can help prolong the service life of the part and reduce maintenance costs.
- Improved fatigue strength means that the part can withstand cyclic loading without cracking or breaking, making it ideal for high-stress applications.
- Reduced friction and improved corrosion resistance can help improve the performance and efficiency of mechanical components in harsh environments.
- Greater dimensional stability means that the part will maintain its shape and size even under extreme conditions, ensuring a precise fit and function.

Overall, induction hardening is a versatile and effective technique that can yield numerous benefits for manufacturers across many industries.

The Many Industries

Induction hardening is commonly used in the manufacturing of gears, shafts, and other components that are subject to high levels of stress and wear. It is also used to harden the surfaces of cutting tools, such as drill bits and saw blades.

In addition to the industries mentioned above, induction hardening is also widely used in the aerospace and automotive industries. It is used to harden the surfaces of engine components such as camshafts, crankshafts, and connecting rods. This process helps to increase the fatigue life of these critical components and ensures that they can withstand the extreme conditions that they are subjected to.

Induction hardening is also a popular choice for manufacturers who want to improve the wear resistance and high strength of their products. By selectively hardening only the areas of the component that are subject to stress and wear, manufacturers can reduce the overall weight of the component while still maintaining its strength and durability.

Overall, induction hardening is a versatile and effective method for improving the performance and lifespan of metal components in a wide range of industries.

A Brief Overview: Induction Heating's History

The origin of induction heating dates back to the early 1800s when Michael Faraday discovered electromagnetic induction. However, it wasn't until the late 1800s that the first induction heating patent was filed by Nikola Tesla. From there, induction heating technology continued to evolve with the development of new materials and the advancement of electronics.

Today, induction heating processes are used in a variety of industries including metallurgy, automotive, and food processing. Some of the benefits of induction heating include faster heating times, precise temperature control, and energy efficiency.

As technology continues to advance, it's likely that induction heating will become even more prevalent in modern manufacturing processes.

Our In-House Heat Treating Capabilities

We have the capability to heat treat your forged components internally, so you can acquire the mechanical and physical qualities necessary for your specific application or industry. Without finding another supplier to complete your heat treating – saving you time and money.

These capabilities include processes such as normalization, quenching and tempering, annealing, as well as induction hardening.

Here are some additional points to consider:

- Normalizing is a process where we heat the component to a specific temperature and then cool it in still air. This helps to refine the grain structure of the metal and improve its overall strength and toughness.
- Quench and temper involves heating the component to a high temperature, then rapidly cooling it in a quenching medium such as oil or water cooled. This creates a hard, brittle surface layer which is then tempered by reheating to a lower temperature. This process improves the component's wear resistance and toughness.
- Annealing is a process where we heat the component to a specific temperature and then cool it slowly in a furnace. This process helps to relieve stress in the metal and improve its ductility and toughness.
- Induction hardening is a specialized process where we use an induction copper coil to heat only the surface layer of the component. This creates a hard, wear-resistant surface layer while leaving the core of the component relatively soft and ductile.

Our team possesses both the necessary skills and state-of-the-art equipment to handle your heat-treating requirements with precision and proficiency.

Posted on May 26, 2023 by lsmith

Benefits and Applications of Induction Hardening Technology

The benefits of induction hardening include:

Induction hardening is a rapid heating process that uses high-frequency electricity to heat the surface of a metal part to a temperature above its transformation point. This results in the formation of a thin, case hardening with a tough and ductile core.
The process can be used on a wide range of ferrous and non-ferrous materials, including steel, cast iron, brass, and aluminum.
The increased hardness and wear resistance of the hardened surface can help prolong the service life of the part and reduce maintenance costs.
Improved fatigue strength means that the part can withstand cyclic loading without cracking or breaking, making it ideal for high-stress applications.
Reduced friction and improved corrosion resistance can help improve the performance and efficiency of mechanical components in harsh environments.
Greater dimensional stability means that the part will maintain its shape and size even under extreme conditions, ensuring a precise fit and function.

Overall, induction hardening is a versatile and effective technique that can yield numerous benefits for manufacturers across many industries.

The Many Industries

Overall, induction hardening is a versatile and effective method for improving the performance and lifespan of metal components in a wide range of industries.

A Brief Overview: Induction Heating's History

As technology continues to advance, it's likely that induction heating will become even more prevalent in modern manufacturing processes.

Our In-House Heat Treating Capabilities

These capabilities include processes such as normalization, quenching and tempering, annealing, as well as induction hardening.

Here are some additional points to consider:

Normalizing is a process where we heat the component to a specific temperature and then cool it in still air. This helps to refine the grain structure of the metal and improve its overall strength and toughness.
Quench and temper involves heating the component to a high temperature, then rapidly cooling it in a quenching medium such as oil or water cooled. This creates a hard, brittle surface layer which is then tempered by reheating to a lower temperature. This process improves the component's wear resistance and toughness.
Annealing is a process where we heat the component to a specific temperature and then cool it slowly in a furnace. This process helps to relieve stress in the metal and improve its ductility and toughness.
Induction hardening is a specialized process where we use an induction copper coil to heat only the surface layer of the component. This creates a hard, wear-resistant surface layer while leaving the core of the component relatively soft and ductile.

Our team possesses both the necessary skills and state-of-the-art equipment to handle your heat-treating requirements with precision and proficiency.

Posted on May 26, 2023May 26, 2023 by lsmith

The Key to Reliable and Productive Construction Equipment

The construction industry demands heavy-duty equipment that can withstand the rigors of harsh environments and heavy workloads. At Southwest Steel Processing (SSP), we manufacture forgings that are critical components of construction equipment such as mining teeth and track links.

In this article, we will discuss the importance of forgings in construction equipment and why choosing forged components over casted components is the superior choice. We will also highlight the importance of American-made and reshoring efforts for OEMs of construction equipment. Lastly, we will share a case study that showcases the benefits of SSP's single-source solution for machined track links.

The Importance of Forgings in Construction Equipment

Forgings offer superior strength, durability, and reliability compared to castings. These qualities make forgings the ideal choice for construction equipment components that are subjected to heavy loads, shock, and wear.

The process of creating forgings involves heating and shaping metal under high pressure, which results in a finished product that is much denser and material strength stronger than castings or other components made through different manufacturing processes.

This high-pressure forging process allows the metal to take on a specific shape and size, while also producing a uniform grain structure throughout the metal, meeting the customer demands. This uniformity results in a final product that is less prone to cracking or breaking under stress, making it the ideal choice for critical components in construction equipment, such as mining teeth, track links, and other vital components.

The strength and durability of forgings ensure that these components can withstand the harsh conditions and heavy use they are subjected to on construction sites, ultimately increasing the safety, reliability, and productivity of the equipment.

Unlike forgings, castings are created by pouring molten metal into a mold and allowing it to cool and harden, resulting in a less-dense material that is more prone to defects and failures. Because of the casting process, the resulting material often has a less uniform grain structure and may contain voids or other imperfections that can weaken the material and make it more susceptible to stress cracking, corrosion, and other forms of wear and tear.

In addition, the cooling process during casting can cause residual stresses in the material that can cause it to warp or deform over time. As a result, castings may be more likely to fail prematurely or require frequent maintenance and replacement, which can lead to increased costs and downtime on construction sites and propose safety concerns for construction workers operating the equipment. Compared to castings, forgings offer a superior level of strength and durability, making them the preferred choice for critical components in construction equipment.

The importance of high-quality components in construction equipment cannot be overstated. By withstanding harsh conditions and heavy loads, forged components offer a longer service life and lower total cost of ownership than castings. According to industry research from the Forging Industry Association (FIA), forgings can last up to 20 times longer than castings, making them a smart investment for OEMs of construction equipment.

The Benefits of American-Made and Reshoring Efforts

Choosing American-made components for construction equipment can provide many benefits, including higher quality, faster lead times, and stronger supply chain relationships. Reshoring efforts can also help to reduce reliance on offshore suppliers and ensure that critical components are readily available when needed.

While many companies have turned to overseas suppliers to reduce costs and increase profit margins. Intended as a cost-effective solution, it can also lead to a variety of negative impacts on the supply chain. Longer lead times, increased shipping costs, and quality issues can all arise from working with overseas suppliers.

In addition, the COVID-19 pandemic has highlighted the importance of having a reliable domestic supply chain. According to a survey by Thomasnet.com, 83% of North American manufacturers are now considering reshoring their operations to ensure greater supply chain resilience and increase their pandemic preparedness.

By choosing United States manufactured components, construction companies can reduce their reliance on offshore suppliers and ensure that they have access to high-quality forgings when they need them. SSP's commitment to American-made forgings and reshoring efforts means that our customers can trust us to provide reliable and high-quality components, manufactured from American raw materials, for their construction equipment.

Case Study - Single-source Solution for Machined Track Links

SSP's single-source solution for machined track links, case study, provides a prime example of the benefits of forgings for construction equipment components. In this case study, SSP worked with an OEM of construction equipment to provide machined track links that were manufactured using our superior forging processes.

As a result, the OEM was able to reduce lead times, increase productivity, and ensure the reliability of their equipment. This case study demonstrates the benefits of working with a trusted partner like SSP for all of your construction equipment component needs.

Read our case study: Single-source Solution for Machined Track Links

Conclusion

Choosing forgings over castings is the superior choice for construction equipment components. Forgings offer superior strength, durability, and reliability compared to castings, which can pose significant risks to equipment and workers. By choosing American-made forgings and working with a trusted partner like SSP, OEMs of construction equipment can ensure that their equipment is reliable and productive.

Don't forget to check out SSP's industry pages and read our case study on single-source solutions for machined track links to learn more.

Posted on May 26, 2023May 26, 2023 by lsmith

The Importance of Forgings in the Mining Industry

Forgings are an essential component of the mining industry. In the mining industry, forgings are used for a wide range of applications, including buckets, shovels, excavators, bulldozers, and other mining equipment. Steel forgings are used by the original equipment manufacturer of mining equipment. They can also be consumed in the aftermarket to repair or enhance equipment that is out in the field.

The Importance of Durable Components in Mining Equipment

Mining equipment is subject to extreme conditions that can cause significant wear and tear. From harsh weather conditions to the intense physical demands of mining operations, every component of mining equipment must be able to withstand the elements. The failure of a single component can result in significant downtime for repairs and replacements, which can lead to lost productivity and decreased profitability. It is therefore essential that all components of mining equipment are manufactured to withstand these conditions, including mining teeth.

Components that are not able to withstand the elements of mining operations are at risk of breaking or failing, which can cause significant damage to the equipment and pose a safety risk to workers. In addition to the direct costs associated with repairs and replacements, equipment downtime can result in lost productivity, missed deadlines, and reduced profitability.

At Southwest Steel Processing, we understand the importance of manufacturing components that are able to withstand the harsh conditions of the mining industry. Our high-quality forgings, including forged mining teeth, are designed to provide superior strength, durability, and reliability.

Forgings: The Superior Choice for Mining Equipment Components over Castings

When it comes to manufacturing components for mining equipment, forgings are the preferred choice over castings due to their superior strength, durability, and reliability. While both forgings and castings are common manufacturing methods for producing metal components, there are significant differences between the two processes that make forgings the superior choice.

Forgings are created by shaping and compressing metal under extreme heat and pressure. This process produces a material with a grain structure that is aligned to the shape of the part, providing superior strength and durability.

Castings, on the other hand, are created by pouring molten metal into a mold and allowing it to cool and solidify. While castings are cheaper and easier to produce than forgings, they are generally weaker and less reliable.

Mining Teeth: Forged to Last

Mining equipment is subject to extreme wear and tear, making the strength and durability of forgings particularly important. One area where forgings are particularly useful in the mining industry is in the manufacturing of mining teeth. Mining teeth are the small, pointed structures that are affixed to the edges of buckets and used to break up and move large amounts of rock and earth.

Forged mining teeth are significantly stronger and more durable than cast mining teeth. They are able to withstand the high levels of impact and wear that occur during mining operations, resulting in a longer lifespan and increased productivity for mining equipment. In fact, research has shown that forged mining teeth can last up to three times longer than cast mining teeth.

The benefits of using forged mining teeth are clear. They increase the lifespan of mining equipment, reduce downtime for repairs and replacements, and ultimately improve the overall efficiency and profitability of mining operations. Southwest Steel Processing has a long history of providing high-quality forgings for the mining industry, including forged mining teeth.

A Leading Component Manufacturer in the Mining Industry

Southwest Steel Processing, LLC is well known in the forging industry and is proud to be based in the USA. The company has been serving the mining industry and other critical industries and is committed to providing American-made forgings of the highest quality.

With recent trends in reshoring and a renewed focus on supporting domestic manufacturing, OEMs of mining equipment can benefit greatly from partnering with Southwest Steel Processing.

In addition to the strength and durability of forged mining teeth, OEMs can also benefit from the single-source solution offered by Southwest Steel Processing. The company provides a complete range of services, including heat treatment processes and machining, ensuring that OEMs receive a finished product that meets their exact specifications.

Southwest Steel Processing's commitment to quality, reliability, and American-made products makes it an ideal partner for OEMs of mining equipment. By using forged mining teeth over castings, OEMs can increase the lifespan and efficiency of their mining equipment, ultimately resulting in increased profitability and success.

To learn more about how forgings in the mining industry can boost productivity growth and Southwest Steel Processing's single-source solution for heat-treated mining teeth, visit our website and read our business case study on the topic. We are proud to serve the mining industry and look forward to partnering with OEMs to provide high-quality forgings for years to come.

By choosing Southwest Steel Processing as a trusted partner, OEMs of mining equipment can ensure that their equipment is able to withstand the elements and perform at the highest level.

Advantages of Forging Compared to Casting

Posted on April 14, 2023April 20, 2023 by lsmith

Forging vs. Casting

Forging and casting are two popular methods used to manufacture products. While both methods have their own advantages and disadvantages, there are several benefits of forged products over casted products. Here are some points to consider:

Strength: Forged products are stronger than cast products due to the process of shaping metal under high pressure, which improves its grain flow structure and makes it denser. This makes forged products more durable and long-lasting than casted parts.
Material properties: Forged products have better material properties compared to casted products. The forging process aligns the grain structure of the metal, which enhances its mechanical properties, such as toughness, ductility, and fatigue strength.

The Science Behind The Forging Process

Forging processes employ mechanical force to shape metal billets, such as rolling, pressing, hammering, or similar techniques, while they remain solid. This heating and deformation process refines the internal grain structure of the metal by allowing metallurgical recrystallization to occur. This results in a more uniform structure throughout the metal form, giving it greater strength and resistance to impact and shear damage.

The benefits of forging processes are numerous, making it a popular choice for shaping metal billets.

Forged metal parts are known for their high strength and durability, making them ideal for use in high-stress applications. The uniform grain structure that results from the forging process also makes the metal more resistant to fatigue and cracking, which can be critical in applications where failure is not an option.

Because the metal is shaped while it is still solid, forging can create parts with a high degree of accuracy and detail, which can be important in critical industries such as aerospace or medical device manufacturing.

There are a variety of forging techniques available, each with its own strengths and limitations. For example, rolling can be used to create long thin parts while hammering is better suited to creating complex shapes and profiles.

Finally, it's worth noting that forging processes can be more energy-efficient than other metal-shaping techniques, such as casting. Overall, the combination of energy efficiency, strength, and flexibility makes forging a highly attractive option for manufacturers who are looking to reduce their environmental impact while still producing high-quality parts.

It's also important to note that while forging produces stronger and more durable parts, it may not be suitable for creating highly complex shapes or intricate designs. In these cases, casting may be the better option.

Casting: An Effective Method for Producing Complex Parts

The process of metal casting involves pouring molten metal directly into an existing mold. The cast metal then cools and hardens into a solid state the exact shape of the mold. Manufacturers choose from various types of molds based on order size and part complexity.

Although metal casting has been used for centuries, it is now primarily used for parts that are too large or unwieldy for metal forging. Casting is an ideal method for creating intricate geometries that cannot be produced through the application of force alone.

Benefits of metal casting over forgings in certain scenarios, when it comes to creating metal parts, casting can be an excellent alternative to forgings, particularly because of the following benefits:

Fewer Restrictions on Size and Complexity: Castings can be created for parts of virtually any size or complexity level, making it a versatile option.
Greater Range of Metal Options: A wider range of specialty alloys can be used in castings since chrome, nickel, and molybdenum can be more easily incorporated into the molten metals.
Cost-Effective for Low-Volume Production: Castings are ideal for producing small production runs more cost-effectively, particularly since the tooling is cheaper than the equivalent forging dies.

Ultimately, the decision between forging and casting comes down to a variety of factors, including the specific requirements of the project, the available budget, and the desired end result.

By carefully considering all of these factors, you can choose the best production method for your project and ensure high-quality, reliable results.

Overall, while casting may be a more cost-effective option for certain products, forging offers unique benefits in terms of strength and material properties that cannot be obtained in any other way. Forged parts are superior and are preferred in critical application areas where the parts must perform at the highest level.

For more information on our forging capabilities contact us.

Automation in the Forging Industry

Posted on March 28, 2023March 28, 2023 by lsmith

Automation has revolutionized the forging industry by increasing Quality, and efficiency and reducing labor costs. Automated robots use computer-controlled technology to produce high-quality metal forgings with precision and consistency.

This has led to improved safety, reduced waste, increased energy efficiency, and increased production capacity. The use of automation also allows for greater customization and flexibility in the manufacturing process. Overall, automation has played a significant role in the modernization of the forging industry.

Southwest Steel Processing is one of the few fully automated, high-volume custom forge shops in North America. We specialize in manufacturing quality forging components, all while maintaining fast lead times. Our dedication to automation and efficiency allows us to offer customers top-notch, high-quality, forged components quickly and reliably.

Even though forging is one of the oldest metalworking methods, it still proves to be highly efficient in today's day and age.

The History

Forging is the procedure of shaping metal without letting it fully melt. The metal stays solid while an operator uses metal forming techniques like hammering, rolling, or pressing. Forging has many variations, often involving heating the metal to high temperatures to make shaping easier.

Dating back to at least 4000 BC, and likely even earlier, early humans practiced the art of forging metals like bronze and iron to create hand tools and weapons for warfare. Forging during this time period was completed by hand.

During the 19th century, forge smiths were skilled at hand and open die process of wrought iron and became adept at hammer welding to create large shaft forgings.

The Bessemer steel-making process, invented in 1856, revolutionized the industry by providing a low-cost supply of steel for production. The first cavity steel using a closed die process began in the United States in 1862 for the Colt revolver components.

The industrial revolution caused significant changes to the industry, as new and improved tools and methods were developed. Initially, hammers were powered by a line shaft, but the invention of more compact electrical motors enabled each hammer to be operated separately, resulting in increased productivity and better organization of the production area.

World War II had a positive impact on the development of better equipment as the industry was absolutely essential to the war effort.

The invention of solid-state electrical induction heaters in the latter half of the 20th century resulted in increased productivity through better dimensional control and higher throughput in the processes.

The Industry Today

Today, the industry relies heavily on the use of automation in the metal forming process. Automated processes can enhance a company's productivity, decrease expenses, and enhance the quality of its products. The use of automated forging allows for precise temperature and pressure control, resulting in reliable and consistent parts.

The modern forging industry has achieved higher levels of control and forging efficiency with computer-controlled automation, as well as updated designs of induction heaters that utilize modern computing power. This has enabled the industry to produce a wide range of components in various materials for use in the railcar, mining, construction, and energy sectors.

Automating forging operations can significantly increase productivity, with potential increases from several hundred pieces per hour to up to 3,000 depending on the product type.

Value-added features like quick die changes should also be considered an aspect of forging automation, allowing the manufacturer to minimize nonproductive time and produce quality parts economically.

Automation in the industry has also helped to improve safety by reducing the number of manual tasks performed by workers, minimizing human error, and enhancing the precision and consistency of the manufacturing process. This has led to a decrease in accidents and injuries in the workplace.

The SSP Advantage

SSP manufacturing lines are fitted with robotic material handling automation to achieve consistent and repeatable quality, capable of producing forgings ranging from 30 to 300 pounds. Ajax/CECO/Erie Press, our sister company, is the leading supplier of forging equipment in North America. They provide us with top-quality forging presses and exceptional service and support.

Our automated forging process has been shown to enhance tensile strength, fatigue strength, versatility, and uniformity, providing numerous benefits like high volume production.

According to a University of Toledo study, forged parts have 26% higher tensile strength compared to cast-iron components, enabling them to withstand more tension without tearing.
When subjected to heavy-duty operating conditions, forged components exhibit greater fatigue strength and a longer lifespan compared to components made by other methods.
Forging techniques offer great versatility in manufacturing a wide range of products, both big and small. Opting for casting instead of forging just to achieve a desired shape is seldom necessary.
Forged components have a more consistent uniform composition and structure compared to cast ones, resulting in a longer lifespan.
Automated processes enable the manufacturing of a large quantity of forged components.

Automation solutions in the forming processes have revolutionized manufacturing by providing repeatability, reliability, and efficiency. Our process is highly automated, ensuring that every step is executed with precision and consistency, resulting in high-quality products. From start to finish, our automated system enhances our ability to produce parts quickly and effectively.

For more information on our automated process contact our trusted sales team today.

Optimized Forging Production with High Volume Techniques

Posted on March 22, 2023March 22, 2023 by lsmith

Steel forgings are an essential part of our manufacturing industry. These complex metal parts are created by applying extreme heat and pressure to a raw material, shaping it into a final product with a specific design and desired shape. Forgings are used in a wide range of applications, from Railcar, Oil & Gas, Gear, Mining, and Construction industries. They are known for their high strength, durability, and reliability and are used in critical application areas.

As one of the few fully automated, high-volume custom forge shops in the North American forging industry, Southwest Steel Processing (SSP) manufactures quality forged components with fast lead times. We manufacture custom high-quality forge parts using advanced automation, machinery, and computer-controlled systems.

All SSP's forging lines are equipped with material handling robotic automation to ensure repeatable, consistent quality with capabilities to manufacture different types of forgings from 30-300 pounds. Because we’re fully automated, we can produce precision forgings at a high volume – up to 2,000 parts per day, per forging line with decreased dimensional variation among parts while increasing all-around productivity. That quality and volume of our metal forging translates to cost-savings and improved quality for our customers. This makes us an ideal supplier for mass production of critical components.

Advantages

One advantage of our high-volume forgings is their ability to withstand extreme stress and pressure. These parts are designed to handle high loads and can be used in harsh environments where other materials may fail. This makes them ideal for use in the oil and gas industry, where high pressure and extreme temperatures are common.

Our forgings are designed to have excellent dimensional stability. This means that they maintain their shape and size even under extreme temperature changes. This makes them ideal for use in critical components in the construction / mining industry, where any deformation or warping can cause serious damage.

Being a domestic supplier for high volume forgings is a benefit to our customers because forged parts are utilized in demanding applications that allow for zero defects—domestic suppliers have the ability to work directly with their clients to determine the best solution to fit their needs. SSP has the capacity and the technological ability to produce custom forged parts for their clients in a seamless process ensuring that output meets Customer and Industry demands.

The Process

All of our forging equipment was manufactured under the ParkOhio holdings umbrella which makes us vertically integrated within the holding company this enables us to work swiftly with our customers ensuring a quality experience.

Forging involves several steps, including preheating the raw material, applying pressure to shape it, and then cooling it down. The raw material used for forging can be any metal or alloy steel that can withstand the high temperatures and pressures involved in the process, including steel, titanium, and aluminum.

In conclusion, forgings are a critical component of many exacting industries. Southwest Steel Processing is a leading custom forging provider, offering high-volume, high-quality forgings for a variety of industries. With years of experience and a commitment to superior craftsmanship, our expert team of engineers and technicians are dedicated to creating the best possible forged components for our customers.

To find out more about or high-volume forging capabilities contact us today to talk to our experienced sales team.

Bringing It Back Home: Exploring the Advantages of Reshoring

The history of offshoring

Reasons for offshoring

The Advantages of Domestic Manufacturing

Forgings Made Domestically

Benefits and Applications of Induction Hardening Technology

Benefits and Applications of Induction Hardening Technology

The Key to Reliable and Productive Construction Equipment

The Importance of Forgings in the Mining Industry

Forging vs. Casting

The History

The Industry Today

The SSP Advantage

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