Heavy & Large Forgings — Open Die Manufacturing, India
Shivam Forge manufactures heavy hot forgings and large open-die forgings for power generation, mining, oil & gas, steel plant, and heavy machinery applications. Large shaft forgings, roll forgings, flanges, and pressure vessels components. 10 kg to 500 kg. Alloy steel, stainless, carbon steel. ISO 9001:2015. CIF worldwide.
Heavy forgings — defined broadly as individual forged components exceeding 50 kg — are required by power generation plants (turbine shafts, generator rotors), mining operations (drill collars, crusher shafts, excavator pin assemblies), oil & gas facilities (wellhead spools, riser pipe sections, pressure vessel components), steel plants (roll forgings, pinion shafts, coupling flanges), and heavy machinery OEMs (press ram forgings, hydraulic cylinder blanks). Shivam Forge's open-die and closed-die forging capability encompasses the heavier end of precision forgings — from 50 kg shaft forgings to 500 kg flanged structural components.
Open-die shaft forgings for power generation (turbine drive shafts, pump drive shafts), mining (conveyor drive shafts, ball mill drive shafts), and heavy machinery (crane slewing shafts, winch drum shafts). Materials: 42CrMo4 (most common for 50–500 kg shafts), 34CrNiMo6 for high-torque applications, C45 for medium-duty shafts. Rough-turned to +5 mm machining stock on journal OD. UT tested per EN 10228-3. EN 10204 3.1 MTC. Weight range: 50 kg to 500 kg.
Forged steel rolls for rolling mills (hot rolling, cold rolling, plate mills), rubber calender rolls, and plastic sheet calender rolls. Large open-die forgings turned to drawing. 42CrMo4 for standard rolls; tool steel (1.2311, H13) for high-hardness tooling rolls. Critical OD straightness ≤0.05 mm/m TIR. Brinell hardness uniformity ±20 HBW across roll face. 100% UT. EN 10204 3.1. Large turning on our CNC lathe with 700 mm swing.
Large weld-neck, blind, and slip-on flanges in Class 600, 900, 1500, and 2500 (ANSI B16.5) or PN 40–PN 250 (DIN EN 1092) for high-pressure oil & gas, petrochemical, and power plant applications. Size range: NPS 4" to NPS 24" (DN 100 to DN 600). Materials: C45, A105 (ASTM), F11/F22 (Cr-Mo alloy), SS 316L. 100% UT + MT. ASME B16.5 dimensional inspection. EN 10204 3.1 / ASME 3.1 MTC.
Heavy hydraulic cylinder forgings for mining excavators (boom cylinder, arm cylinder blanks), offshore jack-up rig jacking cylinders, and press hydraulic cylinder forgings. Large bore hollow forgings (drilled or core-forged) in 42CrMo4 with wall thickness 50–200 mm, ID 80–500 mm. Honed bore available. UT tested per EN 10228-3. EN 10204 3.1. Export to mining equipment OEMs in Australia, USA, and Germany.
Pin forgings for excavator boom-to-arm, arm-to-bucket, and bucket-to-tip joints (50–200 kg each). Crusher jaw die holder forgings, SAG mill trunnion forgings, and grinding ball mill shell flange forgings. 42CrMo4 Q+T for excavator pins. Manganese steel (Hadfield Mn13) for crusher wear parts. Tight pin bore tolerances H7/h6 for pin-bushing clearance. CIF Jebel Ali, Sydney, or Hamburg for mining OEM delivery.
Steam turbine casing flange forgings, turbine impeller blanks, generator rotor shaft sections, and coupling disc forgings for power plant applications. Materials: P91 (9Cr-1Mo-V) for high-temperature steam conditions, 42CrMo4 for lower-temperature drive components, SS 316L for condenser components. Charpy impact at -40°C for low-temperature service. UT Class 3 per EN 10228-3. ASME VIII / PED pressure equipment documentation available.
All heavy forgings (>50 kg) are 100% ultrasonically tested per EN 10228-3 Class 2–4 or ASTM A388. DGS (Distance-Gain-Size) method for accurate reflector sizing. Longitudinal and transverse scanning on turned forging surface. Acceptance criteria per EN 10228-3 or customer specification. UT operators qualified per EN ISO 9712 Level II. Test report with scan records and defect map provided as standard document.
Representative cross-sections from heavy forgings are macro-etched to verify forging structure: absence of pipe, dendritic segregation, or internal cracks; forging grain flow alignment; and confirmation of solid forging without internal porosity. Etching per ASTM E340 or DIN 50602. Photograph archived in production record and provided to customer. Macro examination is mandatory for all heavy shaft forgings and roll forgings.
Tensile test (EN ISO 6892-1): UTS, YS, elongation, and reduction of area measured at ambient temperature. Charpy impact (EN ISO 148-1): 3 specimens at specified temperature (typically -20°C or -40°C for low-temperature applications). Brinell hardness: multiple positions across forging cross-section to verify heat treatment uniformity. All tests on production-matched test pieces (forged and heat-treated with the production lot).
Heavy forgings — components exceeding 50 kg single piece weight — are the backbone of India's industrial infrastructure: power plants use forged turbine shafts and generator components; mining operations use forged excavator pins, crusher shaft forgings, and ball mill components; oil & gas plants use heavy flanges, valve body forgings, and wellhead structural components; and steel plants use roll forgings, pinion shaft forgings, and coupling disc forgings. Shivam Forge's open-die forging capability and CNC turning infrastructure supports heavy forging supply in the 50–500 kg range across all major industrial alloy steel grades.
The quality requirements for heavy industrial forgings are more demanding than standard precision forgings because the consequence of forging defects (internal cracks, piping, dendritic segregation) in large components is more severe — heavier parts carry higher loads, and replacement is expensive and operationally disruptive. Shivam Forge addresses this with mandatory 100% ultrasonic testing (EN 10228-3) on all heavy forgings, macro structure examination of representative cross-sections, full mechanical testing (tensile, Charpy impact, Brinell hardness), and EN 10204 3.1 material certification with production batch traceability. These quality measures match what power plant engineers, mining OEM procurement teams, and oil & gas equipment fabricators require.
For export markets — particularly Germany, Australia, the USA, and the UAE — heavy forging logistics require different handling than standard precision forgings. Components 200–500 kg typically ship on wooden skids in FCL 20' or 40' containers (4–6 pieces per container). Very large individual pieces (>1,000 kg, outside standard capability) may be quoted via associate forging partners. FCL container from Mundra to Hamburg: 15–20 days. To Sydney: 20–25 days. To Houston: 25–30 days. To Jebel Ali: 7–10 days. All with EN 10204 3.1 and full export documentation.
For heavy forging enquiries — please send your drawing (with weight estimate), material specification, heat treatment requirement, NDE class (UT per EN 10228-3 or ASTM A388), and quantity to sales@shivamforge.com. We will return a CIF port-of-discharge quotation within 24 hours for standard enquiries. For large or complex heavy forgings, allow 48 hours for full cost calculation including rough machining, NDE, and special alloy billet procurement. Our heavy forging team handles mining, power, oil & gas, and steel plant sectors with proven export experience.
Shivam Forge's current heavy forging capability covers components up to approximately 500 kg single piece weight in our open-die forging process. For specialised very large forgings (>500 kg), we work with associate forging plants in Rajkot. Our standard heavy forging range: 50–300 kg for closed-die profiles, 50–500 kg for open-die shaft and disc forgings.
Yes — 100% UT is standard for all heavy forgings (>50 kg). We perform ultrasonic testing per EN 10228-3 (Classes 2, 3, or 4 as specified) or ASTM A388 for US-standard forgings. DGS method for reflector sizing. UT operators qualified per EN ISO 9712 Level II. Test report with acceptance criteria and defect-free confirmation provided with every heavy forging shipment.
Heavy forging material capability: 42CrMo4 (most common — shaft, cylinder, gear blanks), 34CrNiMo6 (high-torque applications), C45/C60 (medium-duty), S355NL/J2 (structural), SS 316L (stainless heavy flanges), Duplex 2205 (chemical plant heavy components), P91 (high-temperature power plant). Special alloys on request with extended lead time for billet procurement.
Yes. We supply heavy flange forgings to ANSI B16.5 (weld neck, blind, slip-on) in Class 150 through Class 2500, NPS 2" to NPS 24". Also DIN EN 1092 PN 40 to PN 250 in DN 50 to DN 600. Materials: A105 (carbon steel), F11/F22 (Cr-Mo alloy), SS 316L (stainless), 42CrMo4. EN 10204 3.1 / ASME A3.1 material certification. 100% UT + MT as standard.
Yes. Large bore hydraulic cylinder forgings for mining excavators (Caterpillar, Komatsu, Hitachi, Liebherr supply chains) in 42CrMo4 — bore ID 80–500 mm, wall thickness 50–200 mm, length 300–2000 mm. Honed bore to H7 tolerance available. UT tested for internal defects. EN 10204 3.1. Export to Australia, Canada, USA, Germany, and South Africa mining OEM supply chains.
Standard heavy forgings in common alloy steels (42CrMo4, C45): 6–10 weeks from order. This includes billet procurement (1–2 weeks for standard grades), forging (1–2 weeks), heat treatment (1 week), rough machining/turning (1–2 weeks), testing (UT, mechanical, 1 week), and documentation. For special alloys (SS 316L, Duplex, P91): 8–14 weeks due to billet procurement lead time.
Yes. Heavy forgings are exported worldwide — primarily to Germany (power generation, mining machinery), Australia (mining excavators), UAE (oil & gas), USA (pressure equipment), and the UK (North Sea oil & gas). CIF Hamburg, Jebel Ali, Los Angeles, Sydney, or Rotterdam. Heavy forgings typically ship on flat-rack containers or in OOG (out-of-gauge) breakbulk for very large pieces. ISPM-15 wooden skid packaging standard.
Yes — on project basis with appropriate billet procurement lead time. P91 (9Cr-1Mo-V, Grade 91) forgings for high-temperature steam system flanges, valve bodies, and piping components require careful heat treatment (normalise + temper to specific hardness) and full ASME III / EN 10028-2 documentation. EN 10204 3.1 with Charpy impact at 20°C and creep rupture data if specified. Lead time: 12–16 weeks for P91 due to specialty billet.
Why Choose Shivam Forge
Shivam Forge delivers precision hot-forged components from our integrated Shapar, Rajkot facility — covering forging, CNC machining, heat treatment, and quality inspection under one roof.
