Power generation systems use rotating equipment, pumps, valves, gearing, fluid-handling components, and other mechanical assemblies that may operate under load, pressure, heat, and repeated use. Each component has its own material and manufacturing requirements.

Walker Forge provides custom steel forging for power generation OEMs and suppliers. We manufacture built-to-print steel components using closed-die forging, with engineering, in-house tooling, heat treating, precision machining, and metallurgical testing to support production.

Send us your print or 3D model, material specification, anticipated annual quantity, and secondary operation requirements. We can review the component and determine how our forging capabilities fit the program.

Power generation equipment uses mechanical components to transfer motion, control fluids, connect assemblies, and support equipment operation. Forged steel is commonly used for parts that require consistent mechanical properties and repeatable production. The Forging Industry Association identifies electric power generation and transmission as applications for forgings, including shafts, rings, discs, fittings, and other configurations.

Walker Forge manufactures custom forgings to customer specifications. Products across our existing markets include:

• Input and output shafts
• Transmission and timing gears
• Pump bodies
• Valve bodies
• Balls
• Tees
• Seats
• Check valves
• Ring gears
• Pinions

Geometry, steel grade, mechanical-property requirements, annual volume, machining, heat treatment, and inspection requirements can all affect how a power generation forging is produced.

Walker Forge develops each custom forging around the customer’s print and specifications rather than supplying off-the-shelf components.

Material selection is an important part of a custom forging program. The required steel grade depends on the component’s mechanical properties and operating requirements. Walker Forge works with special bar quality, or SBQ, steel across carbon, alloy, and stainless steel grades sourced through approved mills. Our available materials include more than 1,000 combinations of steel grades and sizes.

Carbon Steel Forgings

Carbon steel can be an economical option when its mechanical properties meet the component’s requirements.

We work with several carbon steel families, including 1000, 1100, 1200, 1300, and 1500 series grades. Carbon and manganese content, combined with heat treatment, can achieve different hardness and tensile-strength characteristics.

Alloy Steel Forgings

Applications requiring different combinations of strength, toughness, hardenability, wear resistance, or temperature performance may require alloy steel. Walker Forge’s alloy steel capabilities include 4000, 5000, 8000, 9000, and 52100 series grades.

Elements such as chromium, nickel, molybdenum, vanadium, and boron can affect steel properties depending on the grade and application requirements.

Stainless Steel Forgings

Stainless steel may be specified for applications that require corrosion resistance, strength, or performance at elevated temperatures.

Walker Forge works with 300 series, 400 series, and precipitation-hardening stainless steels, including 17-4 and 15-5 grades.

Customers provide the required material specification. Walker Forge develops the forging process around that material, the part geometry, required properties, and production needs.

A repeatable custom forging process starts before production tooling is built. Walker Forge can support multiple stages of production, including engineering, tooling, forging, heat treatment, machining, and testing.

Engineering & Tooling

Customers typically provide a print or 3D model along with the raw material designation or specification. Our engineering capabilities include forge process design, tool design, 3D modeling, QForm simulation, and gauge and fixture design.

Forging simulation helps engineers evaluate material flow before production tooling is finalized. That information is used to develop the forging sequence and tooling design for customer review. We also design, manufacture, and heat treat forging dies in-house, keeping tooling directly connected to the forging process.

Closed Die Forging

Walker Forge specializes in closed die forging, also known as impression die forging.

Heated steel moves through a progressive series of dies that form the required geometry and control material flow. The forging process also develops the grain structure within the component.

Closed die steel forgings can provide repeatable geometry and mechanical properties for components produced in ongoing quantities. Grain flow can also follow the shape of the forged part rather than being cut through as it may be when a component is machined entirely from bar or plate. For OEM programs, the process has to remain repeatable from one production run to the next.

Heat Treating for Required Properties

A forged component may require heat treatment after it leaves the press to achieve specified material properties.

Walker Forge offers heat treating processes including:

• Normalizing
• Quench and temper
• Stress relief and annealing
• Carburizing
• Vacuum hardening
• Induction hardening

The appropriate process depends on the steel grade and required mechanical properties.

Machining the Forged Component

Some power generation forgings require features that cannot be completed through forging alone. CNC precision machining can produce bores, holes, surfaces, slots, and other required features after forging and heat treatment.

Customers can keep machining within the same production program instead of sending the forging to another supplier for additional processing.

Power generation component specifications may include requirements for material chemistry, microstructure, hardness, strength, impact properties, or other metallurgical characteristics. Walker Forge operates an ISO/IEC 17025-accredited metallurgical lab that supports our forging and heat-treating operations.

Testing capabilities include:

• Metallographic analysis
• Tensile testing
• Yield testing
• Charpy V-Notch testing
• Chemical analysis
• Macro-etch testing
• Hardness testing

These resources allow Walker Forge to evaluate materials and verify required properties as part of the same production program.

A power generation component may require forging, heat treatment, machining, and testing before it is ready for the next stage of production. Walker Forge can provide those capabilities within the same manufacturing operation.

Our capabilities include engineering, in-house die production, closed die forging, heat treating, precision machining, and metallurgical testing. Keeping more of these operations under one roof can reduce outside processing and simplify sourcing for OEMs and suppliers.

It also allows requirements for forging, heat treatment, machining, and testing to be considered together when the production process is developed.

The forging process must also match the program’s production requirements. Walker Forge operates 13 forging press lines ranging from 850 to 4,000 tons. Our production capabilities support programs ranging from several thousand parts per year to approximately 750,000 parts annually.

Walker Forge maintains ISO 9001:2015 certification, with documented quality systems supporting our manufacturing operations. For new and existing programs, we can review the material, geometry, anticipated quantity, and required secondary operations before developing the production approach.

Power generation components can have different material, mechanical, dimensional, and production requirements. Walker Forge starts with the requirements of the part.

To begin an evaluation, send us your:

• Part print or 3D model
• Material designation or specification
• Anticipated annual quantity
• Mechanical-property requirements
• Heat-treatment requirements
• Machining requirements
• Testing or inspection requirements

We can review the component and determine how our custom steel forging, impression die forging, engineering, heat treating, machining, and metallurgical capabilities fit the program.

Explore our other forging markets or contact us to discuss your power generation forging requirements.