OPEN DIE FORGE

BHLER ONE SOURCE

FROM THE MELT TO THE FINISHED PRODUCT
Forging specialists are at work in BHLERs open die forge.
Here is where metallurgical expertise, over 100 years of experience in special steels and a passion for precise machining
come together.
The result: high-precision components made from materials
we tested and developed. The integrated manufacturing
process from melt to finished product offers the possibility
of developing new materials for specific applications and
guarantees high quality and safety standards. The advantages
for our customers are also apparent in our processes: one
single contact team is at your side from the enquiry through
technical consultations to the offer, from the order to the
delivery and invoicing processes.
In short, your solution provider, a centre of excellence for
special components for the most demanding applications.

OUR STRENGTH
YOUR ADVANTAGE

YOUR MARKET OUR SEGMENT:

ENERGY
For tomorrows energy

Typical products for energy applications

Meeting todays energy demand while at the same time

being sensitive to the needs of the environment is one of the
challenges we face today. Energy-efficient and cost-effective
turbines gas, steam or hydro-powered form the basis of
environmentally friendly and economical energy production.

Compressor and turbine discs, compressor components, high

pressure and intermediate pressure rotors, monobloc rotors,
shaft ends, hollow shafts, housing components, coolant
pump parts, valve and pump bodies, pump shafts, drilled bars
and more.

In turbines, materials are used under the most extreme thermal and mechanical loads. For such extreme conditions,
BHLER has developed high temperature materials, such
as 9-12 % chromium steel grades, nickel based alloys, which
guarantee optimum material properties. We can therefore
count the worlds most renowned turbine manufacturers
among our customers.

Material types used:

9 12% Cr steels
3 3.5% NiCrMoV steels
1 2% CrMoV steels
Soft martensitic steels
Precipitation hardening steels
Austenitic stainless steels
Ni-base alloys

The same applies for components in nuclear power plants,

where BHLER manufactures parts for the primary circuit with
the highest safety and quality requirements in the industry.

THE HEAT IS ON

ENERGY: MATERIALS FOR YOUR

DEMANDING APPLICATIONS
BHLER grade

Market grade

Standards
ASTM
Others

Industry Specifications

Heat treatable steel grades

V116
V128SA

26NiCrMoV11-6

1.6948

26NiCrMoV15-6 mod.

1.6957

SEW 555

Stainless chromium steel grades

N350

X17CrNi16-2

1.4057

AISI 431, UNS S43100, AMS 5628

N400

X5CrNi13-4

1.4312

UNS S41500, DIN EN10250-4

N403

X3CrNiMo13-4

1.4313

UNS S41500, DIN EN10250-4

N700

X5CrNiCuNb16-4

1.4542

AISI 630, UNS S17400, AMS 5604, JIS SUS630,

DIN EN 10250-4

N701

X5CrNiCu15-5

1.4545

UNS S15500, AMS 5659

1.6946

SEW 555

1.6945

SEW 555

A182-F6 NM

PH grades

XM-12

Creep resiting steel grades

D102

30CrNiMoNi5-11

D111

25CrMoV3-8

D623

22CrMoNiWV8-8

9 12% Chromium steel grades

X12CrMoWVNbN10-1-1

1.4906

SEW 555, COST E

T507

X14CrMoWVNbN10-1

1.4902

SEW 555, COST F

T550

X21CrMoV12-1

1.4926

SEW 555

T552

X11CrNiMo12

1.4938

UNS S64152, AMS 5719

X19CrMoNbVN11-1

1.4913

BS S150, AECMAFE-PM36

1.4944, 1.4943
1.4980

AISI 660, UNS S66286, AMS 5525, AMS 5731, AMS 5732

1.4306

UNS S30403

T505SC

COST FB 2

T559
T560

Austenitic steel grades

T200

X4NiCrTi25-15

A182-F316 LN

A415
A604SJ

A286

X2CrNi19-11

A759

X6CrNiNb18-105

A760

X6CrNiNb18-10

F304L

1.4553
F347

1.4550

UNS S34700

Nickel-base alloys
Inconel 617

L617
L625

NiCr22Mo9Nb

2.4856

UNS N06625, AMS 5599, AMS 5666, Inconel 625

L718

NiCr19NbMo

2.4668

UNS N07718, AMS 5662, AMS 5663, AMS 5664,

Inconel 718
6

TESTING AT ITS BEST

YOUR MARKET OUR SEGMENT:

OIL AND GAS
The chemistry of life

Typical products

The exploration and extraction of fossil fuels from the bottom

of our oceans, the manufacture of plastics or the processing
of drinking-water have become common place. Only when
these services are disrupted do we notice the extent of our
reliance on them. Therefore it is important to offer materials
specially designed for highly corrosive environments and
extreme mechanical stresses to the industry.

Components for mooring systems (swivels), valve bodies,

tubing hangers, hollow bars, hollow shafts, y-pieces, components for centrifugal separators, stabilizers, non-magnetic
shafts, impellers, discs, flanges.

BHLER grade

Market grade

Standards
ASTM
Others

Industry Specifications

Heat treatable steel grades

N400

X5CrNi13-4

N404

A182-F6 NM

1.4312

UNS S41500, DIN EN10250-4

X4CrNiMo16-5-1

1.4418

AFNOR Z6CND16-05-01

N700

X5CrNiCuNb16-4

1.4542

AISI 630, UNS S17400, AMS 5604, JIS SUS630,

DIN EN 10250-4

N701

X5CrNiCu15-5

1.4545

UNS S15500, AMS 5659

PH grades

XM-12

Nickel-base alloys
L625

NiCr22Mo9Nb

2.4856

UNS N06625, AMS 5599, AMS 5666, Inconel 625

L718

NiCr19NbMo

2.4668

UNS N07718, AMS 5662, AMS 5663, AMS 5664,

Inconel 718

1.3964

UNS S20910

Non-magnetic steel grades

P501

X2CrNiMoNNb21-16-5-3

P503

X2CrNiMoNNb23-17-6-3

XM-19

1.3974

Duplex and super-duplex steel grades

A903

X2CrNiMoN22-5-3

A911

X2CrNiMoCuWN25-7-4

F51

1.4462

UNS S31803, AFNOR Z2CND22-5 AZ

1.4501

UNS S32760

SEA WATER RESISTANT

YOUR MARKET OUR SEGMENT:

AEROSPACE
Safety accepts no compromise

Typical products

Manufacturing components for aviation and space programs

requires the highest technological standards, strict quality
management setup and a great deal of responsibility from
the people involved in order to meet the requirements of the
worlds most significant manufacturers of aircraft engines.

Helicopter rotor shafts, turbine shafts, stub shafts, casing

and cover turbine pump starters (Ariane V), drive train shafts,
pancake discs for prototyping.

BHLER grade

Market grade

Standards
ASTM
Others

Industry Specifications

Heat treatable steel grades

V124SC

40NiCrMo6

AISI 4340

UNS G43400, AMS 6414

V132

41SiNiCrMoV7-6

V140

40NiCrMo6

V358

39CrMoV13-9

N700

X5CrNiCuNb16-4

1.4542

AISI 630, UNS 17400, AMS 5604, JIS SUS630,

DIN EN 10250-4

N701

X5CrNiCu15-5

XM-12

1.4545

UNS S15500, AMS 5659

N709

X3CrNiMoAl13-8-2

XM-13

1.4534

UNS S13800, AMS 5629

T670

X5CrNiMoCuNb14-5

XM-25

1.4594

UNS S45000, BS S143

1.4933, 1.4938
1.4939

S151, S538, AISI XM-32

A286

1.4943, 1.4944
1.4980

UNS S66286, AMS 5731, AMS 5732

AISI 4340

1.6928

AMS 6257, AMS 6419

1.6565

UNS K23028, AMS 6414

1.8523

3 S132

PH grades

Creep resiting steel grades

T552

X12CrNiMoV12-3

T200

X4NiCrTi25-15

Maraging steel grades

V720

X2NiCoMo18-9-5

Marage 300

1.6354

UNS K93120, UNS K93160, AMS 6521, AMS 6514

V723

X2NiCoMo18-8-5

Marage 250

1.6359

UNS K92890, AMS 6512

Nickel-base alloys
L625

NiCr22Mo9Nb

2.4856

UNS N06625, AMS 5599, AMS 5666, Inconel 625

L718

NiCr19NbMo

2.4668

UNS N07718, AMS 5662, AMS 5663, AMS 5664,

Inconel 718

10

HIGH FLYING MATERIALS

11

YOUR MARKET OUR SEGMENT:

EXTRUSION
Complex solutions

Typical products

BHLER is the world leader in tool steel manufacturing and

research. This experience is incorporated into our extrusion
products. With highly sophisticated FEM analysis tools we
simulate your process conditions to provide the right solutions.

Fully equipped containers, mantles, liners, stems, refitting

services.

BHLER grade

Standard
DIN

Industry Specifications
BS

AISI

W300

1.2343, X38CrMoV5-1

BH11

H11

UNS T20811

W400

1.2343

BH11

H11

UNS T20811

W302

1.2344, X40CrMoV5-1

GH13

H13

UNS T20813

W303

1.2367, X38CrMoV5-3

W403

1.2367, X38CrMoV5-3

W320

1.2365, X32CrMoV3-3

BM10

H10

UNS T20810

W326

1.2323, 48CrMoV6-7

W350
W360
W720

1.2709, 1.6354

W750

1.2779, X6NiCrTi26-15

L718

2.4668, NiCr19NbMo

L901

2.4662, NiCr13Mo6Ti3

UNS K93160, UNS K93120, ASTM Marage 300

660

ASTM A286, UNS 566286

AMS 5662, AMS 5663, AMS 5664, UNS N07718,
ASTM B637, ASTM B670

HR53

AMS 5660, AMS 5661

12

SIMPLY THE BEST

13

FLOW OF MATERIAL
Melting

Secondary metallurgy

Casting

Special Melting

VOD

ESR

Ingot casting
(electrodes, ingots)

EAF 50t

Remelting

VIM

Ladle furnace

HCC

VID 13t

AOD converter
VAR

STATE OF THE ART TECHNOLOGY

Rolling and Forging

Heat Treatment

Machining

Testing

Dispatch

Stock

52 MN Press

RFM
Multiline
Rolling Mill

Shipment
Cogging Mill

PRODUCTION PROGRAM
State-of-the-art equipment
Production facilities Melting
Conventional steel mill

Primary melting in 50 t electric arc furnace

or 14 t vacuum induction furnace treatment
in 50 t argon oxygen decarburisation converter and attached secondary metallurgy

Ingots, HCC casted billets

Special melting and

remelting plant

Primary melting in 16 t vacuum induction

melting furnace, 8 vacuum arc remelting
facilities, 4 open and 4 pressure/protective
gas electro-slag remelting facilities

Vacuum melted electrodes and vacuum remelted ingots max. 16 t for

double and triple melt routes; ingots ESR/PESR max. 32 t;
High alloyed products for high demanding applications in aerospace,
energy, oil and gas and special alloys.

Production facilities Forging

5200 to press

The 5200 ton press with its two integrated

manipulators forms the heart of our forging
shop.

Rotors for turbines and generators, turbine discs, open die forgings,
rings, hollow shafts, discs, round/square/flat bar; forging weight appr.
40 t, max. forging length approx. 12 m

Rotary forging
machine

The rotary forging machine with its high

performance and precise dimensional
tolerances is the ideal forging tool for the
production of steel bars and open die
forgings.

Rotationally-symmetrical and contour shaped open die forgings;

round, square, flat bar; forging weight 8 t max.; max. forging length
21 m

16

Production facilities Heat Treatment

Boogie hearth furnace

30 gas heated furnaces, max. load 150 t,

max. size 11,300 (16,000) x 3,100 x 1,850
(2,500) mm, temperature range 450
1250C,
furnace class accord: AMS 2750-2-4

Forgings to optimise microstructure and mechanical properties

according to customer specification

Spray hardening
equipment

Length 1.0 10 m, diameter 250

1,100 mm, max. load 30 t
Spraying with water-air mixture or
compressed air

Rotors and shafts to achieve rotationally symmetrical structure

formation, minimal deformation and the possibility to adjust different
specific structural properties on a single piece

Production facilities Machining

Turning

1. Five CNC vertical turning and boring

lathes: max. 2,900 x 1,900 mm
2. Two CNC horizontal lathes without
tailstock: max. 1,000 x 400 mm
3. Four small/medium CNC horizontal
lathes (one with milling device)
max. 1,000 x 6,000 mm resp.
700 x 10,000 mm
4. Five large CNC horizontal lathes
(one with milling device)
max. 2,000 x 12,000 mm

Components for steam and gas turbines (discs, rings, hollow shafts,
rotors, housings), components for nuclear, extrusion, oil & gas and
aviation applications

Boring, milling

One CNC milling and drilling machine

max. 2,000 x 3,000 x 4,000 mm, max. weight
25 tons

Extrusion components

Deep hole drilling

Two drilling machines

max. 400 x 8,000 10,000 mm, max.
weight 15 tons

Aerospace, energy, oil & gas, nuclear and extrusion components

Sawing

Three band saws

max. 1,800 x 6,000 mm, max. 30 tons

Discs, housings, rotors, steel bars

Container relining
centre

Max. size of parts: dia 2,000 mm x 2,300 mm

Range of temperature: max. 520 C
Max. weight: 20 tons

Extrusion container

Manufacture of
specimens

Fourteen turning and milling lathes

Test specimens for mechanical tests

Thermal stability
testing

Checking the stability of turbine rotors at

elevated/operating temperatures

Rotors for steam and gas turbines up to 1,300 mm dia x 6,000

(10,000) mm heated (total) length, max. weight 20 t

Ultrasonic equipment
(UT)

1. Automatic ultrasonic testing: two

ultrasonic testing facilities for internal
defects (NDT) with automatic drive and
data acquisition system
2. Manual ultrasonic testing: for internal
defects (NDT)

Discs, rings and hollow shafts, max. dia 3,200 mm, height
2,200 mm, max. weight 35 t

Magnetic particle
equipment (MPI) dye
penetrant testing (FPI)

Surface defects testing with magnetic

particle or dye penetrant inspection (visible
or fluorescent method)

Forgings in all dimensions i.e. shafts, discs, rotors

Measuring equipment

Dimensional checking

Microscope

Scanning electron microscope (SEM) for

investigations of the microstructure

Mechanical testing
equipment

Checking the mechanical properties of the

material on state of the art automatic testing
equipment

Quality control

17

Forgings in all dimensions i.e. shafts, discs, rotors

ULTIMATIVE FORGING
52 MN press

Rotary forging machine

The heart of the open die forge is our 5200 t forging press,
where materials are shaped to meet exact customer demands.
Forged pieces are used whenever the requirements for the
mechanical properties of certain components are high.

With this most modern and unique production line, BHLER

is venturing into a new dimension of forged bars and open die
forgings.

We at BHLER are well aware of these requirements and offer

you custom-made open die forgings or round and flat steel
bars in high alloyed materials. Piece weight from 3 to 30 tons
can be produced to order.

With its high throughput and precise dimensional tolerances,

BHLER will now be able to manufacture forgings from 110
to 700 mm in diameter and a maximum of piece weight of
8,000 kg in contured shapes and multiple pieces as well.
The maximum forging force of 2,000 t, the high-performance
and rapid manipulators for precisely moving parts or ingots
during the forging process ensure the highest quality and
precision.

18

19

SUPERLATIVE MACHINING
From rough maching to aerospace
as you like it
The machine shop, the highlight at the end of the production
chain. Here is where all of the production steps come together
to be matched to your individual requirements. This guarantees
the full quality control cycle from a single source.
The forged parts are rough machined on state-of-the-art CNC
milling, drilling and turning machines in accordance with the
specifications and drawings.

20

21

PRODUCTION PROGRAM
Weight and size limits
Line of business

Max Diameter
mm / inch

Max length
mm / inch

Max weight
t / lbs

Disc

Energy, Oil & Gas

3,000 / 118.1

650 / 25.6

25 / 55,115

Shaft end

Energy

2,000 / 78.7

15 / 33,069

Rotor shafts

Energy, Oil & Gas, Aerospace, Extrusion

1,500 / 59.0

10,000 / 393.7

18 / 39,683

Hollow shafts

Energy, Oil & Gas, Extrusion

2,000 / 78.7

20 / 44,092

Rings

Energy, Oil & Gas

3,000 / 118.1

25 / 55,115

22

23

QUALITY IS OUR PASSION

Principle of Success

Some of our system and material approvals

All of the planning, testing and productions steps involved in

the manufacturing of forged billets are, of course, included
in our Quality Assurance System. We have been certified
by numerous national and international inspection bodies in
accordance with various national and international standards
such as ISO 9001, EN 29001 and BS 5750/1.

Material approvals

We make sure you can rely on our products.

Quality is an obligation to us.

Institution
VdTV
VdTV
VdTV
VdTV
NORSOK

Certificates
WB 508
WB 479
WB 400
WB 424
M-CR-650

NORSOK

M-CR-650

NORSOK

M-CR-650

NORSOK

M-CR-650

NORSOK

M-CR-650

VdTV

HD-AGA

API

API 6A718

Specification
1.4462 / BHLER A903
2.4602 / BHLER L328
2.4819 / BHLER L330SA
2,4610 / BHLER L333
ASTM A182-F51 /
BHLER A903
ASTM A182-F55 /
BHLER A911
ASTM A182-F53 /
BHLER A913
ASTM A182-F61 /
BHLER A926
ASTM A182-F44 /
BHLER A965
ASTM A564 15 5PF /
BHLER N701
alloy 718 / (BHLER L343)

System approvals
Institution
BSI
BSI
GAZ
TV-Sd

Certificates
FM 00777
FM 62106
P-95-29-07-2001
28.04.2004

TV-Sd

60/2002/MUC

Specification
BS EN ISO 9001
QS 9000
EN ISO / IEC 17025
AD W0 / HP0 / TR100 /
KTA 2301.1
PED 97/23/EG

24

25

RESEARCH
It is the mind that controls the body
Today, to a certain degree, it is possible to design new
materials at the computer. A quantum leap. Targeted use of
simulation programmes allows complex alloying systems to
be captured numerically and to predict the phases which will
appear, their composition and their volume fractions. This
leads to a better understanding of the materials and also
reduces laboratory time and costs during development. In this
way, materials and tailor-made properties can be designed.
State-of-the-art facilities allow materials properties to be
measured which form the basis for the development of alloys
with improved properties. In addition, this data is the indispensable basis for the numerical simulation of metallurgical
processes from which the optimum manufacturing parameters
can be determined.

The development work within the European Cost research

programs is a good basis in working together with customers,
universities and research institutes which has resulted in the
successful development of new generation materials. But
not only steels also Ni-base alloys are also emphasised at
BHLER. In the framework of the European collaboration
works Thermie AD700, BHLER contributed to manufactuing
a full-scale trial forging in alloy 625 for the 700 C power
generation technology. In future BHLER will be a member
of the European KMM-VIN action and will also be involved in
developing other materials for the highest requirements.
We are further involved in material research programmes
together with customers in oil & gas, aerospace and many
other high-demand applications. Based on our long history
of breakthrough innovations in new materials for tooling
applications we are heavily involved in creating totally new
alloying concepts.

26

27

WIEN

Linz
A1

A1
Wien / Vienna

A9

A8

S6

A12
A14

S35

Innsbruck
A10

Graz
A2

Abfahrt / Exit
Kapfenberg

Mariazell
Ma
Mari
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tio ell
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Wi
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Ric pfen
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BHLER
Werk / Work
Kapfenberg

S6

Tanzenbergtunnel

Altstadt
Down Town

SPECIAL STEEL FOR THE WORLDS TOP PERFORMERS

Your partner:

BHLER Edelstahl GmbH & Co KG

Mariazeller Strae 25
A-8605 Kapfenberg/Austria
Phone: +43-3862-20-71 81
Fax: +43-3862-20-75 76
E-Mail: [email protected]
www.bohler-edelstahl.com

Printed on chlorine-free bleached paper having no pollution effects.

Your team

The data contained in this brochure is merely for general information and therefore shall not be binding on the company. We may be
bound only through a contract explicitly stipulating such data as binding. Measurement data are laboratory values and can deviate from
practical analyses. The manufacture of our products does not involve the use of substances detrimental to health or to the ozone layer.

SC 127 E - 01.2013 - 1.000 CD - NOS