Research and development

Sheffield Forgemasters recognises that in global manufacturing today, the only sustainable competitive advantage is the ability to master new developments with speed.

Its presence at the forefront of the world's most technically driven markets is due to more than 150 years of technical leadership. This expertise allows the company to continue developing at the pace demanded by its clients and customers.

Sheffield Forgemasters believes that continual development and improvement is the key to securing its future against mounting competition from low-cost and emerging manufacturers and suppliers.

The company places so much importance on R&D that it spends between five and 10% of its profits on research and development companywide.

Some of the major projects being researched and developed within the company include:

  • Modeling - The integration of industry leading computational fluid dynamic, solidification and elasto-plastic deformation modeling is extending the capabilities whilst optimising the yield and performance of forged steel products.
  • Process Optimisation - Process interrogation and forensic metallurgy are identifying and eliminating potential failure modes. This progressively reduces opportunities for error throughout the manufacturing cycle.

Projects within the nuclear industry currently being developed include:

  • Impellor castings using extremely complex coring arrangements and made from Duplex steel, are being produced. The blade profiles have been generated by direct machining of the pattern from a computer generated solid model.
  • Cast pump casings are set to be produced for the nuclear sector and will be manufactured under the recently achieved ASME quality system certificate holder accreditation. The casting will be produced in CF8A stainless steel to extend the development of this material grade.
  • Large diameter crown castings and stay rings for the hydro market have been added to the foundry's latest product range over the last 12 months. The development continues with the first production of large (7m) diameter band castings.

Research and development within the forgings division continues. Projects include:

  • Cost 536: The alloy development for critical components of environmentally friendly power plant. A European programme to develop steels of the 9-12% Cr class for highly efficient steam power plants with low emissions.
  • Immpetus: The development of spray formed D2 and M3 work rolls. A collaborative programme with Danspray and the University of Sheffield, trial rolls are in operation in Outukumpu Sheffield.
  • DTI Technology Programme: Advanced materials for low pressure steam turbines. The manufacture of  a multi part LP welded rotors at higher strength conditions.
  • Other projects include the development of a 300 tonne ingot for large plate mill rolls and shaped forging of pressure vessel heads using special dies.

These, and other, initiatives are underway to allow Sheffield Forgemasters to surpass the current ‘world's best' standard and set new benchmarks for the products integral to its success.

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