Forged Disc - Building the Solid Foundation for Heavy Equipment

Specializing in ultra-thick plate forgings with diameters exceeding Φ1000mm, we leverage advanced process technologies to solve core challenges in heavy-duty load-bearing applications.

Redefining “Pancake Forgings”: The Art of Load-Bearing

In heavy equipment manufacturing, when a steel plate exceeds 100mm in thickness, it transitions from being called “plate” to a “pancake” requiring specialized forging. Traditional thick plates suffer from inherent flaws like loose core structure and anisotropy. Our disc-shaped forgings overcome this through repeated upsetting and drawing in an 8,000-ton press. Like kneading dough, this process reshapes the metal from its core, achieving crystal structures and mechanical properties as dense in thickness as at the surface.

Core Process: Forging a Solid Base with “Consistent Quality Inside and Out”

The core challenge for disc-shaped forgings lies in “core quality.” We address this through a combination of “high temperature + high specific pressure + multi-directional forging”:

Custom Ingots

For ultra-thick disc components, we require steel mills to use specialized “top-heavy, bottom-light” ingot shapes. The most critical stress-bearing sections of the forging are prioritized in the middle and lower sections of the ingot—where the highest quality steel resides—eliminating segregation bands at the source.

Technical Capabilities:

Application Scenarios: Under Heavy Load, Bearing Critical Responsibilities

Our disc forgings serve as the skeletal framework for these “silent giants”:

Energy & Power: Functioning as cylinder split flanges in ultra-supercritical thermal power units and thrust bearing housings for hydro turbines, maintaining dimensional stability under high temperatures, pressures, or heavy loads.

Heavy Machinery: Serving as gear disc substrates for offshore drilling platform hoisting systems and workbench plates for 10,000-ton hydraulic presses, withstanding extreme alternating loads.

Chemical Vessels: Used as large head blanks and shell sections for coal liquefaction reactors and hydrocrackers, ensuring safety in high-temperature hydrogen-containing environments.

Mold Industry: Serves as the base for large hot-working molds (e.g., aluminum alloy die-casting molds), where its superior core toughness prevents premature cracking.

Defense & Research: Applied in pressure-bearing bases for specialized test equipment and shielding components for particle accelerators, demanding stringent material purity and uniformity.

Several Practical Reasons to Partner with Zhongli

We offer a “Risk Preview” service: During the quotation phase, we proactively disclose production risks associated with high-risk materials or extreme specifications, empowering you to make informed decisions.

Proven track record in enhancing efficiency and reducing costs for clients: We help customers lower expenses by optimizing forging processes.

28 years of forging heritage: Established 28 years ago, we possess extensive expertise in forging and machining.

Next Steps: Submit Drawings to Receive a Feasibility Assessment Report

Please provide your technical drawings or specified technical parameters. Our project engineers will:

Conduct a rapid technical review (response within 24 hours).

Provide detailed process solutions and transparent quotations.

Offer accurate production cycle estimates.