Positions available (shift expansion)

Forging positions open due to expansion of production 

Two candidates will be selected for this position.

Rotary forging is a specialized process performed at our Tipton Forge plant, in Tipton, Indiana. This position is operating the controls of a semi automated process with many variables for the forging process. It requires constant awareness of the process, similar to a machining operation. It is very hands on role, with high operator involvement in the forging process. For example: using known temperatures and practices in creating and documenting processing, adjusting the size or the amount of reduction, checking the process for repeatability, feeding material into the forge and switching forging direction. Sometimes the job entails actually loading material into the bar feed. Changing dies and grips, as well as coordinating the service and repair with machine shop.

Areas that will help a potential operator are math skills pertaining to manipulating algebraic equations. Common application is the delta area used in calculating reduction of area percentages. Understanding stress-strain curves. Understanding die wear and repair in a forging application. Understanding forces and the effects of those forces over larger and smaller surfaces.

While an engineering degree is not a requirement, a general understanding of materials and processes, such as an MET AS degree, would be beneficial but not absolutely required. We do offer tuition reimbursement, for full time employees to attend colleges and tech schools, in fields related to their job or aspirations within the company.

Some on the job training will be provided to familiarize with the roles and duties of day to day operation and maintenance of the equipment.

Health insurance contributions as well as vacation and holiday pay. We have several company events through the year to participate in as well. We are a non-union shop, with many of the same policies that you would find in a union shop. As a small family run company, the owners are expected to perform multiple job duties through the week. We expect our employees to be able to enjoy and value the diversity and flexibility we offer. In the last 32 years we have not had a single layoff. Turnover is very minimal, and we are a tight knit group working towards a common goal.

Official Job Description 

Job Title: Radial Forge Operator
Department: Plant Operations
Reports To: Plant Manager
FLSA Status: Non-exempt
Prepared By: David Morrow

SUMMARY 

Forges various alloy bar stock with radial forging equipment to meet required dimensions and properties by performing the following duties.

ESSENTIAL DUTIES AND RESPONSIBILITIES
include the following. Other duties may be assigned. 


  • Determines operating parameters required to achieve the desired material properties for each work order 
  • Adjusts the furnace to the required operating specifications according to work instruction
  • Removes heated material from furnace and places on radial forge
  • Monitors machine for proper operation 
  • Performs machine setup, maintenance, and repairs
  • Operates radial forge via control panel 
  • Records forge production on manufacturing log. 

SUPERVISORY RESPONSIBILITIES 

This job has supervisory responsibilities over those who assistant in the operation of the furnace and maintenance of the radial forge.

QUALIFICATIONS

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

EDUCATION and/or EXPERIENCE 

High school diploma or general education degree (GED) with one year related experience and/or training.

LANGUAGE SKILLS 

Ability to read and interpret documents such as safety rules, operating and maintenance instructions, and procedure manuals. Ability to write routine reports and correspondence. Ability to speak effectively before groups of customers or employees of organization.

MATHEMATICAL SKILLS 

Ability to add, subtract, multiply, and divide in all units of measure, using whole numbers, common fractions, and decimals. Ability to compute rate, ratio, and percent and to draw and interpret bar graphs.

REASONING ABILITY 

Ability to apply common sense understanding to carry out instructions furnished in written, oral, or
diagram form. Ability to deal with problems involving several concrete variables in standardized situations.

CERTIFICATES, LICENSES, REGISTRATIONS 

None required.

PHYSICAL DEMANDS 

The physical demands described here are representative of those that must be met by an employee to
successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is regularly required to use hands to finger, handle, or feel and reach with hands and arms. The employee frequently is required to stand and sit. The employee is occasionally required to walk, climb or balance, and talk or hear. The employee must frequently lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus.

WORK ENVIRONMENT

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is regularly exposed to moving mechanical parts and extreme heat. The employee is frequently exposed to fumes or airborne particles. The employee is occasionally exposed to toxic or caustic chemicals, risk of electrical shock, and vibration. The noise level in the work environment is usually very loud.

FM-62-01-11 Rev. A


Employer: High Performance Alloys, Inc. 
Contact HR: Sutton Krogstie
Ph: (765) 945-8230
Toll free (USA)  800 HPALLOY  or  800-472-5569
www.HPAlloy.com

High Strength NITRONIC 60 Bridge Hinge Pins

by Grant Kirchner

High Performance Alloys, a distributor of NITRONIC 60 and producer of high strength NITRONIC 60, makes bridge hinge pins for use in high strength applications. Not only is NITRONIC 60, a chromium nickel stainless steel, good for high strength, but it also has good corrosion resistance and great galling resistance. These characteristics of the high strength steel help it to be very effective in construction projects such as bridge repairs and construction. 

Nitronic 60 Hanger Pins and Nuts
The galling resistance is a tremendous bonus to the alloy over other stainless steels as the pin must be able to move with the expansion and contraction of the bridge. The ability of NITRONIC 60 to resist galling and corrosion are tremendous advantages in high strength applications for the continuous lifecycle of a bridge.

High Performance Alloys has produced high strength 
NITRONIC 60 to over 200 KSi yield. High Performance Alloys is also a domestic distributor, stocker of NITRONIC 60 that allows for quicker turnaround times here in the United States.

NITRONIC is a registered trademark of AK Steel.

Read an interesting datasheet on ACUBE 100 today

The datasheet on AMS 5918 (ACUBE 100) indicated that the ductility of the material is severely impacted from even a small amount of cold work :
Cold Working
High strength levels can be achieved in ACUBE 100 alloy through cold working processes. It should be noted that a significant loss of ductility results from even small amounts of cold work.
Taken from http://cartech.ides.com/datasheet.aspx?i=101&c=TechArt&E=341 on 10/28/2014
After locating the material specification in a cold formed bushing requirement, I was interested in what the AMS 5918 was. I was even more surprised after reading the above excerpt. The AMS 5918 is the warm worked variation (in certain cases, warm working can have undesirable precipitates occur). Warm worked materials have 7 to 30% Elongation and 10 to 24% Reduction of Area.  These low Elongation and Reduction of Area numbers indicate a stiffness or brittleness that would indicate fatigue and shock resistance may be an issue.

Wear and galling resistance is toted as primary benefits of the grade, but it has a very low galling threshold. Galling threshold is listed as greater than 20KSI. While the >20KSI threshold (per ASTM G98) is impressive when compared to type 316 which is >1KSI and 440C only attains 18KSI, it is also telling when MP35N has a threshold of 5KSI. I must note that NITRONIC 60 in the annealed condition (AMS 5894) has a threshold of >50KSI (primarily dictated by its yield strength, rather than an overall hardness achieved).

We perform hot, warm and cold forging processes in Tipton on our various equipment, so its always good to stay abreast of materials that are being utilized by industry.

Forging super alloy and super stainless

Forging super alloy and super stainless is not an easy job. Working these alloys usually requires twice as much power as other alloy or stainless products. This is due to the alloys being very strong through their chemical composition - higher alloy grades inherently have greater value. That inherent value is before you even cut it, heat it and form it to the shapes and sizes required. Having the right size billet starting stock makes a difference in the overall forging time required and the resultant mechanical properties the item will have. The chances a forging house will be able to make a small part successfully is dependent upon the input billet, how many pieces regularly required and over how many years it will run.

When requesting a quotation for a forging, it is very helpful to provide the finished dimensions, and allow sales to provide the oversize amount needed to guarantee the part can be machined. It may be more stock to remove than you would like, but you should only have to machine it once. Some materials are tougher to forge and machine than others. If you have never machined the item before, this is a good time to talk to sales about machinability and tooling needs. Many times machine shops will win an order due to machine time underestimate. Some of these alloys will take twice as long to machine, due to the removal rates are not as good with the higher tensile and yield strengths.

Forgings can be provided in a multitude of ways and they have different amounts of value added service. Forging option for open die forgings are as follows: oversized with allowance to finish, rough ground, rough machined, and finish machined per print. We also can perform inspections at this stage (above and beyond the AMS/ASTM material requirements). Whether it is an ultrasonic to various criteria, charpy V notch, magnetic permeability, dye penetrant or radiograph - it is always best to use these types of inspections early when they can be performed early and with less complex geometry.

Most of our customers require actual mechanical testing for their forgings. The controlling specification would have an indication of whether testing is required, but the application or usage of that part is what should dictate the need. A non critical part could be verified that is has been supplied correctly through a simple hardness check. The options for actual mechanicals are testing from a forged coupon, using a prolongation of the piece or cut from item, and actually destroying a piece to determine properties.  Separately forged test coupons are normally the route taken, and provide a great insight to the properties of the actual forging. The actual forging should be hardness tested and compared to the coupon hardness to correlate the two properties. Using a prolongation or destroying the sample will provide results that can certify a batch as well, these would be used for more critical type requirements and help show how the material is responding in "as used" cross sections.

A Few “Must-Knows” About Our Company

   Tipton Forging is a division of High Performance Alloys, located in Tipton Indiana. If you were to call us today, the phone will be answered by a High Performance employee - so please do not be confused. High Performance Alloys (HPAlloy) is a small family owned company, serving the aerospace, nuclear, marine, chemical and petroleum industries since 1984. HPAlloy started out as a service center, primarily serving the small quantity needs of many shops across the country. No one company needed a great amount of the products we carried, but the one thing they had in common was the need to repair or build small quantities of these materials into their projects. They needed small cuts and short lengths quickly. Thirty years ago, business was done by phone and mail, a formal quote would take over a week to receive.

  We have a great following of customers and friends from over the years. The main company has grown and grown, but most people think of High Performance Alloys for stock needs quickly. We needed to get the message out to the public about the added capabilities of the company, and so a division was born to serve that purpose. The one main difference between the divisions is that Tipton Forge has a basic concept to forge materials quickly and make specialty items in prototype quantities even faster. Historically, the mills had research and development departments that would take care of some of these needs. Unfortunately, most of those R&D departments are only shells of their former selves. They can do some things, but they don't have the manpower required to act quickly anymore. Research and development of materials in the country has been stagnated. There are still needs to have small to medium quantities of items specially produced. That is where we come in, and that is a niche we have been filling for the last twenty years at our own facility. Our company's founding metallurgists had been serving these needs unknowingly since the beginning, only they had no idea the places they would have things made would eventually be phased out or consumed by larger corporations.