Turbine Rotor Discs
Steam and gas turbine rotor disc forgings in P91 (9Cr-1Mo-V) and F22 (2.25Cr-1Mo) Cr-Mo steel. Ultrasonic tested per ASTM A388. OD up to 1,200 mm. Supplied to power equipment OEMs with full material traceability from melt.
100–1500 mm
Disc OD Range
40–60%
Material Saving vs. Bar Machining
ASTM A388
UT Inspection Standard
12+
Export Countries
Near-Net-Shape Disc Forgings from 100–1,500 mm OD
Disc forgings are among the most demanding shapes in hot forging — achieving uniform grain flow tangentially across a large OD while maintaining thickness tolerance requires precise die engineering and controlled forging parameters. Shivam Forge's closed-die disc forging process delivers superior mechanical properties, ultrasonic-testable internal quality and dimensional repeatability for power, railway and commercial vehicle OEMs.
Disc Forgings We Manufacture
Brake Disc Blanks
Commercial vehicle and railway brake disc blanks forged in EN24 (AISI 4340) alloy steel and grey iron equivalent in steel. Consistent density, zero porosity and superior heat dissipation grain structure vs. cast iron alternatives. OD 250–700 mm.
Clutch Pressure Plate Blanks
Heavy-duty clutch pressure plate disc blanks forged in C45 and alloy steel for trucks, tractors and off-highway equipment. Controlled flatness and parallelism within 0.5 mm across face after forging.
Flange Disc Forgings
Blind flange discs and weld neck flange blanks in carbon steel (A105), alloy steel (F11/F22) and stainless (A182 F304/F316) from stock material. Forged to ASTM A181/A182 or IS 2062 as required.
Pulley Disc Blanks
Solid and webbed pulley disc blanks for V-belt, timing belt and flat belt drive systems. Forged in EN8 and EN19 with machining stock of 3–5 mm on face diameters. OD 100–600 mm.
Dam Ring Discs for Bearing Housings
Precision dam ring disc forgings in alloy steel for cylindrical roller bearing housing assemblies. Tight ID/OD concentricity within 0.3 mm TIR, heat treated to 28–32 HRC.
Materials for Disc Forgings
P91 / F91 Cr-Mo Steel (9Cr-1Mo-V)
ASTM A182 F91 — preferred material for high-temperature steam turbine discs operating above 550°C. Superior creep strength and oxidation resistance. Supplied normalized and tempered with hardness 195–245 HBW.
F22 / 2.25Cr-1Mo Steel
ASTM A182 F22 alloy steel for gas turbine discs and high-temperature flanges. Tensile strength 415–585 MPa in annealed condition; 620–795 MPa in Q&T. UT per ASTM A388 Level B acceptance.
EN24 / AISI 4340 Alloy Steel
High-strength Ni-Cr-Mo steel for brake disc blanks and heavy-duty disc applications requiring 900–1,100 MPa tensile strength. Through-hardened and tempered. Impact toughness 60+ J at room temperature.
IS 2062 Structural Steel
Hot-rolled equivalent IS 2062 E250/E350 for structural disc blanks, dam plates and general industrial disc applications where cost is the primary driver and corrosion resistance is secondary.
EN8 / C45 Carbon Steel
Medium-carbon steel for pulley blanks, clutch disc blanks and general disc forgings. Normalized at 870–900°C, achieves 580–700 MPa UTS. Most cost-effective choice for non-critical disc components.
Quality Assurance & Testing
Ultrasonic Testing per ASTM A388
100% volumetric UT on all turbine discs and critical forged disc blanks per ASTM A388. Acceptance to Level B or Level C per customer requirement. Reports provided for every disc.
Dimensional Inspection
OD, ID, thickness, flatness and parallelism verified using calibrated CMM and height gauges. Inspection report with actual vs. nominal dimensions supplied with each consignment.
Hardness Testing
Brinell hardness tested at minimum 3 points per disc on the ID face after heat treatment. Results documented against required HBW range per material and customer specification.
Material Certification
EN 10204 3.1 Mill Test Certificates for all disc forgings. Chemical composition, mechanical properties, heat treatment records and heat/lot numbers fully traceable.
Magnetic Particle Inspection
MPI per ASTM E709 available for surface and near-surface defect detection on brake disc blanks and structural disc forgings. Wet fluorescent or dry powder method.
Near-Net-Shape Disc Forgings from 100–1,500 mm OD
Shivam Forge manufactures precision disc forgings from 100 mm to 1,500 mm OD in Rajkot, Gujarat — supplying power generation, railway, commercial vehicle and industrial OEMs across India and 12+ export countries. Our closed-die disc forging process delivers uniform grain flow tangentially across the disc face, a characteristic that machining from bar stock cannot replicate. For rotating disc applications like turbine rotors and brake systems, this tangential grain flow directly translates to 20–30% better fatigue life compared to machined bar.
Turbine rotor disc forgings represent our most demanding product category. We forge P91 (9Cr-1Mo-V per ASTM A182 F91) and F22 (2.25Cr-1Mo per ASTM A182 F22) Cr-Mo steel turbine discs with full material traceability from the melt heat. Every turbine disc undergoes 100% volumetric ultrasonic testing per ASTM A388 before dispatch. UT acceptance to Level B or C per customer specification — reports provided with each disc, not sampled from the batch.
Brake disc blanks for commercial vehicles and railway rolling stock are forged in EN24 (AISI 4340) alloy steel, heat treated to 900–1,100 MPa tensile strength. The forged disc blank has zero internal porosity — a permanent advantage over grey cast iron brake discs which can contain microshrinkage that initiates thermal cracking under repeated heavy-braking cycles. We supply brake disc blanks with machining stock of 3–5 mm on both friction faces for final machining at the customer's facility.
Near-net-shape disc forging achieves 40–60% material saving against machining from solid bar stock. For high-value materials like EN24, P91 or F22 where billet costs are ₹180–400 per kg, this saving has a direct impact on component cost per piece at quantities above 50 pieces. Shivam Forge works with customers on die design to optimize the forging envelope for minimum flash while maintaining the required tolerances on critical faces.
Shivam Forge's disc forging quality documentation is designed for power equipment and railway OEM approval processes. Every disc forging is supplied with EN 10204 3.1 Mill Test Certificates, dimensional inspection reports, heat treatment furnace charts, hardness test results and — for critical discs — ASTM A388 UT reports. Contact us at +91-9265772827 or sales@shivamforge.com to discuss your disc forging requirement and receive a detailed quotation within 24 hours.
Frequently Asked Questions
What is the maximum OD Shivam Forge can produce for disc forgings?
We manufacture disc forgings from 100 mm to 1,500 mm OD depending on material and thickness. Contact us with your specific drawing for a confirmation of feasibility and lead time.
What materials are used for turbine rotor disc forgings?
Steam turbine discs are typically forged in P91 (9Cr-1Mo-V) or F22 (2.25Cr-1Mo) Cr-Mo steel per ASTM A182. Gas turbine discs may use nickel alloys for very high temperatures. We specialize in P91 and F22 turbine disc forgings.
Why use disc forging instead of machining from bar for turbine discs?
Near-net-shape disc forging saves 40–60% material versus machining from solid bar. More importantly, forging aligns grain flow tangentially in the disc, which provides 20–30% higher fatigue strength than bar-machined discs where grain flow is axial and not optimized for the stress field in a spinning disc.
Do you perform ultrasonic testing on disc forgings?
Yes. All critical disc forgings — turbine discs, brake disc blanks and dam ring discs — are UT inspected per ASTM A388. We provide UT reports with every consignment. Acceptance level (B or C) is set per customer specification.
Can you supply P91 turbine disc forgings with EN 10204 3.1 certificates?
Yes. We supply P91 and F22 turbine disc forgings with full EN 10204 3.1 Mill Test Certificates covering chemical composition, mechanical properties and heat treatment records.
What is the material saving of disc forging over bar machining?
Depending on the disc geometry, near-net-shape disc forging achieves 40–60% material saving over machining from solid bar stock. For expensive alloy steels like EN24 or P91, this represents significant cost reduction per piece.
Do you supply brake disc blanks for commercial vehicles?
Yes. We forge brake disc blanks in EN24 (AISI 4340) alloy steel for commercial truck, bus and railway applications. OD range 250–700 mm. Forged disc blanks have zero porosity and superior heat dissipation compared to grey cast iron.
How do I request a quote for disc forgings?
Send your drawing (PDF or DXF) with material specification, required OD/thickness, heat treatment requirement, UT requirement and quantity to sales@shivamforge.com or call +91-9265772827. We respond within 24 hours.
Why Choose Shivam Forge
Trusted forging manufacturer — Rajkot, Gujarat
Shivam Forge delivers precision hot-forged components from our integrated Shapar, Rajkot facility — covering forging, CNC machining, heat treatment, and quality inspection under one roof.
- Hot forging from quality alloy steel billets (42CrMo4, C45, EN8, SS316L)
- In-house CNC/VMC machining to drawing — ±0.05mm tolerances
- Heat treatment — normalizing, hardening, tempering, annealing
- CMM inspection and full EN 10204 3.1 material certification
- Custom OEM forging from customer drawings — PPAP/ISIR available
- Fast export from Mundra Port — CIF worldwide, FOB India
- Export expertise — Europe, Middle East, Americas, Asia-Pacific