Search Results

Equipment, capabilities and processes for manufacturing steel utilizing the best ladle furnace technology. CAPABILITIES > Steelmaking > STEELMAKING Producing large steel ingots utilizing the best ladle furnace technology. EQUIPMENT AND CAPABILITIES The majority of NAF’s ingots are purchased from Ellwood Quality Steels and shipped hot a few hundred yards between the plants. EQS is North America's most reliable producer of high-quality, low-cost carbon, alloy, tool, and martensitic stainless steel ingots. Low carbon stainless ingots are available from Ellwood National Steel and other approved sources. Every phase of the ASEA-SKF split steelmaking system is highly monitored and closely controlled producing steels with exceptional cleanliness and tight chemistry ranges. The ability to repeat specific alloy content for given grades allows NAF to achieve consistent mechanical property results after heat treatment. The steel cleanliness rivals that achieved only through re-melted refining processes such as ESR and VAR. The melt shop features a modern 45 nominal ton Ultra High Power Electric Arc Furnace with Eccentric Bottom Tapping (EBT). The ladle furnace steelmaking is accomplished with split ASEA-SKF secondary steelmaking equipment: Two ladle refining units A custom alloy delivery system One ladle vacuum degasser THE PROCESS First, scrap is loaded into clam-shell buckets and charged into an ultra-high powered (UHP) eccentric bottom-tapping (EBT) electric arc furnace. After the scrap is melted, carbon and phosphorus are removed under an oxidizing slag. Steel is then bottom tapped slag-free into a preheated ladle. The ladle serves as the refining vessel and is built for both induction stirring and argon bubbling. During tapping, deoxidation and alloy additions are charged into the ladle, followed by a reducing top slag. The ladle is transferred to the first refining station for alloy adjustment and refining. Arc heating and induction stirring at this step ensures homogeneous mixing and interaction between the steel and slag. The ladle is then transferred to a vacuum degassing station whereby hydrogen is removed to a level of less than 1ppm. Combined induction stirring and argon gas bubbling are used during vacuum treatment. After vacuum degassing, the ladle may go to the second ladle refining for calcium wire treatment. Heats are sent to teem at a consistent pre-designated temperature. All ingots are bottom-poured at a controlled rate of rise in big end up, tapered, fluted molds. A teeming car is used to enable faster turnaround and multi-heat ingot pours. Argon shrouding is employed to minimize re-oxidation and the pick-up of nitrogen and hydrogen. < Quality Forging >

North American Forgemasters has the ability to perform chemical, mechanical, non-destructive and dimensional inspection. CAPABILITIES > Testing > NONDESTRUCTIVE AND MECHANICAL TESTING Access to the experts, services and resources you need for quality certified product. EQUIPMENT AND CAPABILITIES Backed by our Partners, NAF has the following in-house capabilities in multiple locations: Chemical Analysis and Metallurgical Testing including Metallography, Grain size, Microcleanliness, Macrostructure, Corrosion, Optical Emission Spectroscopy, Phase Identification and Phase Count Mechanical Testing including Tensile, Dynamic tear, Hardness, Crack Tip Opening Displacement (CTOD), Fracture Toughness (KIC, JIC), Fatigue, Crack Growth, Charpy Impact (700 ft·lbf machine; -321 °F through 200+ °F), Nil-Ductility Transition Temperature (NDT) Level III Nondestructive Testing: Ultrasonic Inspection (UT): Contact A-Scan Testing, Phase Array Magnetic Particle (MT): Wet Fluorescent, Dry Powder Liquid Penetrant (PT): Water Washable Fluorescent, Visible Dye Weights up to 40 metric tons (88,000 lbs.) Dimensional Inspection Elemental Analysis using Optical Emission and X-ray Fluorescence Spectrometry THE PROCESS Prior to manufacturing, many decisions are made regarding material, process planning and production to ensure product performance and conformance to specifications. To validate whether the product meets spec requirements for its intended application, a variety of testing methods are employed as required. Mechanical testing, which is also known as destructive testing, is accomplished by forcing a test sample to fail by the application of various load factors. In contrast, non-destructive testing identifies surface or subsurface flaws and defects without causing harm to the part or material. Reach out to one of our NAF team members for more information. < Heat Treat Machining >

North American Forgemasters produces forgings for nuclear propulsion and reactor components or waste-storage and transport forgings. FORGINGS FOR COMMERCIAL NUCLEAR North American Forgemasters manufactures the entire spectrum of forgings for the commercial nuclear industry, including SMRs. NORTH AMERICAN FORGEMASTERS | WHY CHOOSE US? Leveraging the technical expertise of our JV Partners, the team is knowledgeable in nuclear OEM requirements, including small modular reactors (SMR), post-contract deliverables, in-process hold points and material certification packets. NAF offers precision and commitment that extends to unparalleled support, providing you with a partner dedicated to custom solutions, timely delivery, and continuous collaboration. Trust in our forging mastery to create your nuclear components, from R&D to production parts. NAF delivers unwavering quality and is actively building an ASME Code Section III and NQA-1 compliant quality system. Typical components consumed in these markets are: Shells with integral nozzles Flanges Risers Ultra large support skirts Ultra large storage casks Top, bottom, closure and primary heads Tube sheets Steam plenums Domes Nozzles < Shipbuilding Defense > MARKETS > Commercial Nuclear >

North American Forgemasters has horizontal, vertical and boring lathes capable of machining lengths up to 75 ft. as well as a variety of finish machining operations. CAPABILITIES > Machining > EQUIPMENT AND CAPABILITIES With a full range of downstream machining options, utilizing a combination of CNC and manual machining centers, NAF has the capability to rough machine its largest produced forgings. With a variety of horizontal and vertical turning lathes, vertical and horizontal boring mills, milling machines, horizontal trepanning and boring machines, machining centers and saws, these redundant capabilities reduce the risk for time-critical applications in our customers supply chain. Examples include: A boring lathe capable of lengths to 23 meters (75 ft.) A vertical turning lathe capable of swinging 6.7 meters (264 in.) with 4 meters (157.5 in.) under the rail Horizontal lathes with swings to 3 meters (118 in.) and center to center distance to 30.5 meters (100 ft.) NAF also has over over 30 large machine tools capable of a variety of finish machining operations. Please feel free to reach out to one of our team members for more information about our machining capabilities. THE PROCESS Machining is a broad term used to describe various controlled material-removal processes in which a material is cut to form a desired final shape, size and surface finish. These processes include turning, milling, drilling and grinding and non-traditional machining such as torch and water jet cutting. < Testing Quality > MACHINING FOR ULTRA LARGE FORGINGS A powerhouse of machining capabilities and services. MACHINING FOR ULTRA LARGE FORGINGS A powerhouse of machining capabilities and services.

North American Forgemasters produces forgings for the Power Generation industry - helping to provide the world with the energy they need. MARKETS > Power Generation > FORGINGS FOR POWER GENERATION NAF is well equipped to exceed your power generation forging requirements. NORTH AMERICAN FORGEMASTERS | WHY CHOOSE US? The worldwide need for power generation is increasing in all areas of the world. NAF stands ready to support your large open die forging needs with the latest technology in North America. Demanding operating conditions require forgings made to the highest quality each and every time. Every department understands these requirements and why it is imperative to achieve and exceed customer’s specifications the first time. With decades of cross functional experience, our sales and quality team can provide the fastest, best value proposals in the industry. This fundamental approach is but one of numerous reasons our customers partner with us as their supplier of choice. Some of the forgings that we produce for this industry are: Generator shafts Steam and gas turbine rotor shafts, disks and bucket wheels Jackshafts Exciter shafts Hydroelectric shafts Fan shafts Very large torque tubes Very large compressor shafts and disks < Oil & Gas Shipbuilding >

North American Forgemasters produces steel forged cylinders, sleeves, blind hold cylinders and hollows with weights up to 270,000 lbs., max. O.D. 160 in. and max length 400 in. PRODUCTS > Sleeves & Stepped Hollows > FORGED SLEEVES AND STEPPED HOLLOWS NAF manufactures seamless forged, heavy wall hollow cylinders and sleeves in various customized configurations per customer requirements. Seamless forged hollows are ideal for high-stress applications and harsh environments due to their durability, strength and corrosion resistance. Hollows can be produced in a straight cylindrical shape and with unlimited variations of O.D.s and I.D.s, including tapers. Additionally, NAF offers all downstream processing , including heat treatment, machining and mechanical and non-destructive testing, upon request. Contact us today with your exact specifications, and our team will work with you to capitalize on our capabilities to minimize material waste and reduce process inefficiencies. Max. O.D. Max. Length Max. Weight 160in. 400+in. 325,000+ lbs. < Shafts/Bars Blocks > FORGED SLEEVES AND STEPPED HOLLOWS NAF manufactures seamless forged, heavy wall hollow cylinders and sleeves in various customized configurations per customer requirements. Seamless forged hollows are ideal for high-stress applications and harsh environments due to their durability, strength and corrosion resistance. Hollows can be produced in a straight cylindrical shape and with unlimited variations of O.D.s and I.D.s, including tapers. Additionally, NAF offers all downstream processing , including heat treatment, machining and mechanical and non-destructive testing, upon request. Contact us today with your exact specifications, and our team will work with you to capitalize on our capabilities to minimize material waste and reduce process inefficiencies. Max. O.D. Max. Length Max. Weight 160in. 400+in. 325,000+ lbs.

North American Forgemasters (NAF) is an open-die forge facility that produces billet stock, ring preforms and forged shapes in sizes up to 270000 lbs. CELEBRATING 25 YEARS Proudly serving our nation and the critical markets continuously revolutionizing the world, NAF has pushed the bounds of North American forging capabilities since 1997. LEARN MORE ABOUT NAF NORTH AMERICAN FORGEMASTERS Backed by its JV Partners, NAF is determined to earn and win back a share of the large open die forging needs of its North American customers. Since the '80s most of these parts have been supplied by offshore forgers. LEARN MORE ABOUT NAF PUSHING THE BOUNDARIES OF FORGING Providing consultation, extensive capabilities and new technology to solve your toughest challenges CONTACT US NOW UNPARALLELED CAPABILITIES The only fully integrated manufacturer of open die forgings in the Western Hemisphere SEE OUR CAPABILITIES REQUEST A FORGING QUOTE TODAY Reach out to one of our forging experts today about your requirements. Please send along any specifications and drawings so that we may better understand your request. If you need additional help, contact one of our team members to discuss your toughest challenges or call (724) 658-4703 . EMAIL YOUR RFQ 325,000+ Pounds Max. Forging Weight 240 + Years of Combined Forging Experience 100 + Value-Added Options 25 + Years of Partnership North American Forgemasters (NAF) is a 50-50 joint venture between Scot Forge and Ellwood Group, Inc. As an open die forge facility, NAF produces billet stock, solid and hollow preforms and custom forged shapes in sizes up to 270,000 lbs. Located in western Pennsylvania in New Castle, NAF serves as the only fully integrated manufacturer of open die forgings in the Western Hemisphere. From steel making to finish machining, NAF represents American manufacturing at its finest. CONTACT US Have a question or need a RFQ? Feel free to reach out to one of our team members personally . We'll get an answer for you as soon as possible! phone: (+1) 724-658-4703 email: nafsales@naforgemasters.com address: 710 Moravia Street, New Castle, PA 16101

North American Forgemasters produces forging for surface mining and sub-surface mining from Australia to Canada to Brazil and beyond. MARKETS > Mining > < Machinery Infrastructure > FORGINGS FOR THE MINING INDUSTRY Digging, raising, moving, trucking ... NAF supplies the key components to keep your earthmovers rolling. NORTH AMERICAN FORGEMASTERS | WHY CHOOSE US? The Super-Sized equipment used in this industry is not getting any smaller. When the market demands that your equipment run around the clock, downtime can cost you millions of dollars in lost production. NAF knows your mining assets will be pushed to their engineered potential. Count on our superior manufacturing approaches to guarantee maximum returns for your equipment. Our cross functional teams are experts on component reduction, optimized material selection, and enhanced grain flow and metallurgical morphology. Think of us as an extension of your engineering team! Some of the forgings that NAF supplies are: Gyratory crusher shafts Crusher rolls Walking dragline and shovel shafts Drum/ mine hoist shafts Hoist shafts Hydraulic cylinders Pulverizers

Certified to ISO 9001:2008, PED 2015, DNV MSA and Nadcap for Heat Treatment of aluminum alloys and non-destructive testing. CAPABILITIES > Quality > IMPROVING THE QUALITY OF FORGED PARTS NAF is dedicated to achieving quality results through the strength and commitments of its employees. PROCESSES AND CERTIFICATIONS Initially, North American Forgemasters (NAF) utilized the JV Partners for compliance with a quality management system; however, after 2018, NAF operated under their own documented quality management system that conforms to ISO9001:2015. NAF is certified to ISO9001:2015 and holds a Forging Facility and Process Approval for Marine Applications through ABS. NAF maintains a quality focused culture to ensure systems and processes remain robust and to drive operational excellence. Quality Policy North American Forgemasters (NAF) is committed to providing our customers with products and services that meet their expectations. NAF is committed to organizational compliance with the quality management system (QMS) requirements as outlined in the quality manual and in accordance with the ISO 9001 standard. NAF focuses on the continuous improvement of these six areas to drive best value to our customers:: Safety Quality Lead Times On-Time Delivery Golden Rule Cost NAF’s quality policy is maintained through a comprehensive Quality Management System compliant with International Standard. Performance is monitored and regularly reviewed to ensure our operational standards meet the high-quality expectations of our partners, customers and stakeholders. Downloads Please see the below certification(s) and accreditation(s): ISO 9001:2015 ISO 9001:2015 < Machining Steelmaking > IMPROVING THE QUALITY OF FORGED PARTS NAF is dedicated to achieving quality results through the strength and commitments of its employees. PROCESSES AND CERTIFICATIONS Initially, North American Forgemasters (NAF) utilized the JV Partners for compliance with a quality management system; however, after 2018, NAF operated under their own documented quality management system that conforms to ISO9001:2015. NAF is certified to ISO9001:2015 and holds a Forging Facility and Process Approval for Marine Applications through ABS. NAF maintains a quality focused culture to ensure systems and processes remain robust and to drive operational excellence. Quality Policy North American Forgemasters (NAF) is committed to providing our customers with products and services that meet their expectations. NAF is committed to organizational compliance with the quality management system (QMS) requirements as outlined in the quality manual and in accordance with the ISO 9001 standard. NAF focuses on the continuous improvement of these six areas to drive best value to our customers:: Safety Quality Lead Times On-Time Delivery Cost Golden Rule NAF’s quality policy is maintained through a comprehensive Quality Management System compliant with International Standard. Performance is monitored and regularly reviewed to ensure our operational standards meet the high-quality expectations of our partners, customers and stakeholders. Downloads Please see the below certification(s) and accreditation(s): ISO 9001:2015 NAF Forge Facility ABS Approval NAF Forge Facility DNV Approval Downloads Please see the below certification(s) and accreditation(s): ISO 9001:2015 ISO 9001:2015

North American Forgemasters manufactures components in a variety of material for the nuclear, mining, oil and gas, power generation and general industrial markets. MARKETS > FORGING MARKETS SERVED NAF manufactures components in ferrous and non-ferrous material for the nuclear, mining, oil and gas, power generation and general industrial markets. Commercial Nuclear Shells, flanges, risers, support skirts, storage casks, tube sheets, domes and more. Overview Forgings for reactor components, waste-storage and transport forgings. Read More National Defense Shafts, hollows, uniquely shaped forgings and other complex components. Overview Supplying essential components for national defense programs, NAF is a premier forging partner. Read More Heavy Machinery Hydraulic cylinder housings, pistons, rams, tie rods, spindles, pinions, and more. Overview Forgings for heavy equipment for road construction, forestry, farming, manufacturing, mining, military applications, etc. Read More Mining Crusher and pulverizer shafts and rolls, hoist shafts and shafts for walking draglines and shovels. Overview Forging for surface mining and sub-surface mining from Australia to Canada to Brazil and beyond. Read More Infrastructure Trunnions, gudgeons, pinions, shafts, rings and more. Overview From sea to shining sea, NAF provides the large forgings needed to support dams and other infrastructure projects. Read More Oil & Gas Wye blocks, tension and riser joints, valve bodies, spools, pump bodies and more. Overview Forgings for exploration, extraction, refining or transporting for the Oil & Gas industry. Read More Power Generation Generator shafts, gas and steam turbine shafts and disks, fly wheels, jackshafts, exciter, hydroelectric and fan shafts and more. Overview Forgings for the Power Generation industry... providing the world with the energy they need. Read More Shipbuilding Rudder stock, shafts, tubes, bearings, couplings, rings and more. Overview Forgings for complex vessels such as cruise ships, ferries, mega-yachts, dredgers, submarines, naval vessels and more. Read More

North American Forgemasters, home of the largest open-die press in North America, forges over 100,000 ingot tons per year and is capable of producing parts weighing up to 270,000 lbs. CAPABILITIES > Forging > OPEN DIE FORGING Providing strong, reliable parts - Made in America EQUIPMENT AND CAPABILITIES NAF’s new 90MN (10,120 ton) open die forging press is the greatest tonnage, fastest acting and most reliable in the Americas. The press opening is also the largest with 6 meters (236 inches) of vertical daylight and five meters (197 inches) between the columns. The stroke is 3.1 meters (122 inches). The press is serviced by a 200 metric ton railbound manipulator, a 100 metric ton mobile manipulator and a 230 metric ton overhead crane. The existing, internally designed and built 40 MN (4,500 ton) sister press is serviced by multiple 45 metric ton mobile manipulators. This press has been operational since 1998 and was fully rebuilt in 2013. During its operation, NAF has averaged forging more than 100,000 ingot tons per year making it the most productive press in the U.S. and possibly the world. This is a testament to both the skill of the NAF forging crews and the maintenance staff that maximizes the press uptime. 90 MN (10,120 ton) open die forging press 40 MN (4,500 ton) open die forging press 200 metric ton railbound manipulator 45 metric ton mobile manipulators 100 metric ton mobile manipulator 230 metric ton and other overhead cranes In the press complex there are box type forge heating furnaces and a large car bottom furnace redundancies that employing the latest regenerative burner technology. Continue to the Heat Treatment section to learn more! THE PROCESS Open die forging is a manufacturing process where heated metal is shaped and densified by applying great hydraulic pressure to the part between a top and bottom die. Compared to other metalworking processes, like castings, fabrications or weldments, the forging process inherently produces stronger parts by achieving contoured grain flow and fine grain size and by consolidating porosity in the part. < Steelmaking Heat Treat >

North American Forgemasters produces forgings for complex vessels such as cruise ships, ferries, mega-yachts, dredgers, submarines, naval vessels and more. MARKETS > Shipbuilding > FORGINGS FOR NAVAL AND COMMERCIAL SHIPBUILDING When costly delays are not an option, NAF supplies the parts you need for new ships and ships in dry dock. NORTH AMERICAN FORGEMASTERS | WHY CHOOSE US? Our combined capabilities are truly unmatched when it comes to forgings for the shipbuilding industry. We have extensive military specification knowledge and experience with ABS, DNV and other marine agency requirements. Whether your company is building a new vessel, or making repairs, leverage our experience to maximize your bottom line and shorten your supply chain. Our ingot capabilities and extensive furnace sizes allow us to manufacture the heaviest and longest ship shafting required. These shafts can be up to 75ft (22.8m) long. < Power Gen Nuclear >