An Overview of Flange Manufacturing and Welding

The process of flanges manufacturing is quite complex and must be adhered to rigorously if the manufacturer is to create high-quality components. It is critical for all metal fabricators performing manufacturing and welding of flanges to use high-quality materials from reliable vendors and to have plenty of quality control practices in place to ensure all finished products meet or exceed industry standards.

Casting flanges are known for their high production efficiency and low costs for both medium- and low-pressure pipelines. In high-pressure environments, forged pipes are the better alternative.

A casting flange features iron fillings. After the iron mill is melted down, that molten iron gets poured into a mold where it is then cooled and processed.

Here is a quick overview of how the flanges manufacturing process works, from raw materials all the way through the finished product:

  1. Gathering raw materials: The first step is to collect the raw materials that will be used in the manufacturing process. It is important to order the materials in the correct type, quantity and dimensions to create the flanges needed.
  2. Material inspection: Before the materials can be used in the manufacturing process, they should be carefully inspected with a chemical analysis and a preservation analysis.
  3. Cutting: After careful inspection, the fabrication process can begin with cutting down the materials. They should be weighed, marked and then cut and inspected before being sent on to the forge.
  4. Flange forging: At this stage, the metals are weighed and then placed into the forge to be melted down at the proper temperature.
  5. Heat treatment: While hot, the metal will be normalized, tempered and then put through various tests to ensure it is ready for cooling and further work.
  6. Forging rolling: This step includes a material grade check, weight measurements, temperature check and dimension check after the metal is brought down to proper temperature. The flanges are rolled into their form and sent on for inspection.
  7. Final inspection: During the final inspection the fabricators will double check the dimensions, conduct visual examinations of the condition of the flanges and perform nondestructive tests to ensure durability.
  8. Rust prevention: At this point, the flanges will be either pickled or coated to ensure they resist rust and corrosion and to preserve their condition for a longer time.
  9. Well packing: In this final step, the flanges are officially coated and done and are ready to be packed, inspected and shipped off for delivery.

It’s important to note there are several methods of producing flanges, with both cast flanges and forged flanges having their own merits. The above process can vary depending on the method, but it at least gives some idea of how flanges are created and the steps that go into assuring their quality upon completion.

Interested in learning more about flanges? Get in touch with the team at Metal Works Corporation today with any questions you have about the products we develop. We look forward to working with you soon.