Research & Development

Sheffield Forgemasters’ Research, Design & Technology (RD&T) team provides support to all of the manufacturing areas within the company from steelmaking through to finish machining.

Our work ensures that Sheffield Forgemasters remains a World leader in the manufacture of high quality carbon, low alloy and stainless steel castings and forgings for the most demanding applications.

Computer Simulation of Casting, Metal Forming and Heat Treatment

Our business is characterised by the manufacture of small quantities of large, complex forged and cast components. As a result, full scale trials and prototypes are often too expensive or take too long to produce. Therefore a ‘right first time’ manufacturing capability is essential.

Casting, metal forming and heat treatment: these are the key processes that determine the quality and performance of our products. We can model these processes in detail using the latest computer software in order to design and optimise each step of the manufacturing process. This helps us to achieve ‘right first time’ products with the highest quality and performance and at the same time minimise risk and cost.

Modelling capabilities include:

  • Solidification of castings and forging ingots (Thercast, Magamasoft)
  • Metal forming & heat treatment (Forge, DEFORM, JMatPro)
  • Stress analysis (ANSYS, SolidWorks Simulation)
  • Computational fluid dynamics (ANSYS Fluent)
Internal Research and Development content image
Internal Research and Development content image

Computer Simulation of Casting, Metal Forming and Heat Treatment

Our business is characterised by the manufacture of small quantities of large, complex forged and cast components. As a result, full scale trials and prototypes are often too expensive or take too long to produce. Therefore a ‘right first time’ manufacturing capability is essential.

Casting, metal forming and heat treatment: these are the key processes that determine the quality and performance of our products. We can model these processes in detail using the latest computer software in order to design and optimise each step of the manufacturing process. This helps us to achieve ‘right first time’ products with the highest quality and performance and at the same time minimise risk and cost.

Modelling capabilities include:

  • Solidification of castings and forging ingots (Thercast, Magamasoft)
  • Metal forming & heat treatment (Forge, DEFORM, JMatPro)
  • Stress analysis (ANSYS, SolidWorks Simulation)
  • Computational fluid dynamics (ANSYS Fluent)
Internal Research and Development content image

Industrial Trials and Laboratory Testing

We cannot model everything, so laboratory and industrial scale trials still have an important role in research & development. We have a range of experimental tools and investigative techniques at our disposal and use these to assist our manufacturing areas with carefully designed experiments to optimise products and processes.

Capabilities include:

  • Custom-built induction heating & cooling machine for simulating industrial heat treatments
  • Laboratory chamber furnaces for tempering trials
  • Metallurgical laboratory (optical microscopy, SEM with EDX analysis)
  • Chemical analysis (OES, Leco, hand-held XRF)
  • Quench dilatometer for determining experimental TTT and CCT diagrams
  • Differential scanning calorimetry (DSC)
  • UKAS accreditied test house (tensile, Charpy, hardness, fracture toughness, Pellini drop-weight testing)
Internal Research and Development content image

Industrial Trials and Laboratory Testing

We cannot model everything, so laboratory and industrial scale trials still have an important role in research & development. We have a range of experimental tools and investigative techniques at our disposal and use these to assist our manufacturing areas with carefully designed experiments to optimise products and processes.

Capabilities include:

  • Custom-built induction heating & cooling machine for simulating industrial heat treatments
  • Laboratory chamber furnaces for tempering trials
  • Metallurgical laboratory (optical microscopy, SEM with EDX analysis)
  • Chemical analysis (OES, Leco, hand-held XRF)
  • Quench dilatometer for determining experimental TTT and CCT diagrams
  • Differential scanning calorimetry (DSC)
  • UKAS accreditied test house (tensile, Charpy, hardness, fracture toughness, Pellini drop-weight testing)

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