Forged Weld Neck Flanges
Forged Weld Neck Flanges
Weld neck flanges are a type of flange that are characterized by their long, tapered neck, which provides excellent reinforcement in high-pressure and high-temperature applications due to their reliability and mechanical strength. Forged Components is the industry leader in the manufacturing of weld neck connection flanges.
An overview of our forged flanges and the manufacturing process.
Superior Strength and Durability
- The long neck of the weld neck flange provides additional strength, reducing stress concentration at the base of the flange. This makes them ideal for handling high pressures, temperatures, and fluctuating conditions.
Smooth Flow and Reduced Turbulence
- The tapered neck of the flange gradually transitions into the pipe, minimizing turbulence and erosion at the joint. This helps in maintaining smooth fluid flow and reduces pressure drop, which is critical in piping systems carrying corrosive or abrasive fluids.
Strong and Secure Connection
- Our weld neck flanges are designed to be butt-welded to the pipe, which creates a strong, permanent, and leak-proof connection. This is particularly important in critical applications where safety and reliability are of utmost importance.
Enhanced Fatigue Resistance
- Due to the gradual taper of the neck, the flange provides enhanced resistance to bending and vibration, making it ideal for systems with constant stress or fatigue.
High Temperature and Pressure Capability
- FCI manufactures weld neck flanges are from quality materials such as carbon steel, stainless steel, or high-alloy materials, allowing them to perform reliably in extreme conditions like high temperatures and pressures.
Alignment and Bore Matching
- The bore of the weld neck flange needs to match the bore of the connected pipe, which ensures proper alignment and consistent flow characteristics. This feature helps prevent misalignment, reducing wear and tear on the system. Our quality control process guarantees this alignment.
Manufacturing Process of Weld Neck Flanges
The manufacturing of weld neck flanges involves several critical steps to ensure that they meet the required dimensional tolerances, mechanical properties, and safety standards.
Material Selection and Preparation
- FCI’s first step in the manufacturing process is selecting the appropriate material based on the application requirements. Common materials we stock include carbon steel, stainless steel, alloy steel, and special alloys.
- Raw material is typically procured in the form of cylindrical billets or ingots, which are cut to the required size.
Initial Forging
- The raw material is heated in a furnace to a high temperature to increase its malleability.
- The heated billet is then placed in a forging press, where it is shaped into a rough flange form using an open-die or closed-die forging process.
Forging of the Neck and Body
- The neck of the weld neck flange is formed by placing the rough flange in a die that shapes the neck to the desired taper and length.
- Pressure is applied uniformly to achieve the required dimensions and properties. This process also reduces grain size, enhancing the mechanical strength of the flange.
Piercing the Center Hole
- The flange is pierced to create the bore (center hole) that matches the pipe's dimensions. The bore is carefully machined to ensure precise alignment and smooth surface quality.
Heat Treatment
- After forging, the forged weld neck flange undergoes heat treatment processes such as annealing, normalizing, or quenching and tempering. This step refines the microstructure, relieves internal stresses, and improves mechanical properties like toughness and hardness.
Machining and Shaping
- With Forged Components machining capabilities, the forged flange is machined to achieve the final dimensions, including the bore diameter, outer diameter, and bolt circle diameter.
- Additional features like bolt holes are drilled according to the required standards (e.g., ANSI, ASME, API).
Facing and Finishing
- The facing of the flange (raised face, flat face, or ring-type joint) is machined to provide a smooth surface for gasket seating.
- Surface finishing operations such as polishing or coating may be applied to improve corrosion resistance and appearance.
Quality Inspection and Testing
- Each weld neck flange is subjected to rigorous quality control checks, including dimensional inspections and non-destructive testing (e.g., ultrasonic testing, radiography, dye penetrant inspection).
- Mechanical tests like tensile testing, impact testing, and hardness testing may also be conducted to verify the material properties.
Final Inspection and Certification
- After passing the Forged Components Quality Management System quality inspections, the flange is marked with identification details (material grade, size, pressure class, heat number) and certified according to industry standards (e.g., ASME B16.5, API 6A).
FCI’s weld neck flanges are considered top of the line in the forged products community and are a critical component in many of the industries we serve due to their mechanical strength, resistance to fatigue, and ability to withstand harsh environments. Our design and manufacturing process ensure they can handle demanding applications with precision and reliability.