How Are Flanges Manufactured?

Flanges are built using the three principal methods: casting, fashioning and forging. No matter what method you choose to use, creating the “perfect” flanges involves preparing raw materials, then followed by using precise dimensions.

In order to ensure a secure and quality fit, Flanges are manufactured using three widespread techniques. Herein, we will delve into these strategies as well as the advantages and disadvantages associated with each process before they are packaged up and sent off to clients.

Using Raw Materials For Frange Manufacturing

According to Diversified, the flange manufacturing process starts by focusing on getting high-quality raw materials, which can be sourced in a number of different ways. No matter which route you take, it’s very important that the raw material used for frange manufacturing is quality materials.

Before you start production, the raw materials must pass through a rigorous testing and examination process. This is called a Mill Test Report (MTR), it confirms the chemical and physical properties as well as adhering to all of the minimum requirements specified by applicable standards. The manufacturer will not start until the MTR is reviewed and authenticated, which guarantees quality control at every step of the process.

The most common raw materials used in flange production are:

Aluminum
Mild Carbon Steel
Stainless Steel
Ductile Iron

Common Flange Manufacturing Methods

The creation of flanges involves a process of sculpting and machining, followed by drilling and polishing to very specific requirements. As you learned above, there are 3 methods available for you to use, including casting, cutting, and forging.

Cut Flange Production Method

The process of creating a cut flange begins with the flattening and thinning of steel metal stock using rollers until it achieves its desired plate thickness. The next step is to accurately cut the outer and inner diameters (except for blind flanges, which do not require an ID) by utilizing a torch, laser, or water jet.

Mahr, a company that builds chemical gear pumps, said a lot of products receive flange manufacturing. From gear pumps and sockets to piping, the cut flange method is used when you need precise measurements for products.

By following this methodical sequence, manufacturers can ensure that they produce quality products that meet their customers’ requirements. By cutting, drilling, and serrating the flanges to precise measurements cut manufacturing method offers lower production costs but can lead to more scrap materials waste. While cost-efficient, these cut flanges may not be as sturdy when compared with those produced using other techniques.

Cast Flange Production Method

To produce the flange, we begin with molten metal which is poured into our specially-crafted mold. Once it has solidified and firmed up, the form is opened to reveal a perfectly shaped casting; this then gets machined so that it meets all desired dimensions as well as achieves a smooth surface finish. The production of cast flanges is cost-efficient and creates less waste in the manufacturing process. Yet, due to their internal structure that isn’t as compacted as forged flanges, there may be more defects present. Thus, they are not suitable for applications involving high pressure or temperature; this increases their chances of failing.

Forged Flange Production Method

Forged flanges are produced by heating steel and other metal stock, followed by compression to form the shape from a solid state. This compressing not only enables strength but also creates continuous grain flow throughout each piece. Afterward, they are machined to meet specific requirements per production needs. Although more expensive than alternatives, forged flanges provide superior wear resistance when compared side-by-side with non-forged options.