Step by step to the optimum: the complex process of forging 3 minutes spent reading
Aerospace

Step by step to the optimum: the complex process of forging

Viktoria Steininger
Holds editorial responsibility for blog topics, is researching and writing articles. Her stories give insights into the world of the voestalpine Group.

Engine mounts from BÖHLER Schmiedetechnik GmbH & Co KG are high-quality, special forgings that must later withstand high temperatures and stresses. Their manufacture is highly complex.

Whether it is a nickel-based alloy, a titanium alloy, or high-alloy steel: These materials are considered hard to form due to their sometimes high flow resistance. Forging these materials into aircraft engine mounts requires a combination of expertise in materials, design engineering and manufacturing. BÖHLER Schmiedetechnik GmbH & Co KG brings all of these together under one roof.

Precisely defined detailed manufacturing plans

The design engineers in Kapfenberg work together with the materials scientists and colleagues from Production to define the detailed manufacturing plan for each individual special forging:

voestalpine engine mount production

  • Input material: The steel and titanium alloys arrive in the form of bars. The steel alloys are produced by the neighboring sister company BÖHLER Edelstahl GmbH & Co KG. Titanium- and Ni-based alloys always come from approved suppliers.
  • Preliminary stage production: A rough distribution of volume occurs here; i.e. an initial, rough forming. The preliminary stage is produced on a longitudinal forging machine, on the hammer or on a press.
  • Preforming stage in the pressing tool: The preliminary forging is warmed in the furnace (time and temperature are precisely defined) and then formed in the pressing tool. BÖHLER Schmiedetechnik GmbH & Co KG produces the pressing tools in its own toolmaking shop: Preforming is performed on the hammer, the hydraulic press or the spindle press.
  • Pre-pressing stage in the pressing tool: Now the forging is once again inserted into the furnace and then goes to the hammer or spindle press for final forming. BÖHLER Schmiedetechnik GmbH & Co KG owns the world’s largest spindle press!
  • Final pressing stage in the pressing tool: Next, the forging is once again inserted into the furnace and then onto the hammer or spindle press, where the forging is given its final form. This is followed by heat treatment, testing and pre- and/or final machining.

Quality counts

After the forging is completed, the forged piece is tested and machined. The forging process for an engine mount can last up to 8 weeks. At each stage, parameters that are precisely defined and coordinated with the customer must be adhered with. The heating temperature in the furnace, the degree of formation, cooling times, etc. – the entire process is precisely controlled and documented by Quality Assurance in order to ensure seamless traceability.

The latest video from the voestalpine image and brand campaign focuses on engine mounts we produce for aircraft in Kapfenberg, Austria, and shows them being installed in the Airbus A380 of Emirates Airline. An ongoing blog series offers further insight and background information about the product, the areas of application and the market as well as about Hans Freudenthaler from Böhler Schmiedetechnik GmbH & Co KG, the star of the campaign.

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Viktoria Steininger