ELLWOOD CITY FORGE GROUP - New Castle
With over 100,000 square feet of manufacturing space under roof, our New Castle facility has forging, heat treatment, and machining capabilities to handle the largest forgings that are produced by ECF -- up to 70,000 pounds. Our close proximity to EGI business unit, Ellwood Quality Steels, allows the receipt of ingots hot via an in-house transfer car thus eliminating the need for outside transportation.
A mobile manipulator capable of lifting 150,000 pounds transfers ingots from the heating furnace to the press. The 5000 Ton pull-down press has four columns and a moving crosshead. It is powered by 8 - 600 horsepower axial piston pumps. A fast forge valve provides the capability for high speed plannishing. The press has 180 inches of daylight and 120 inches between columns.
The press is equipped with an 8-station tool change magazine that allows for quick die changes. The top die has the capability of 360 degrees continuous rotation with locking mechanisms at 0 and 90 degree positions. Press controls provide enhanced diagnostics, on-line drawing viewer, and 12-station oscilloscope.
ECFG-New Castle has 2 separate locations for heat treatment - a West location and an East location. The West location has 3 tip-up furnaces and 4 car bottom furnaces. In addition, a 57 feet long tip-up furnace provides the capability to heat treat long products. The polymer and water quench tanks hold 100,000 gallons each and measure 10 feet wide and 50 feet long.
The East location was commissioned in 2008. There are 6 car bottom furnaces that straddle water and polymer quench tanks. Each tank holds 80,000 gallons and measures 10 feet wide and 40 feet long. The quench tank lift tables are rated at 240,000 pounds lift capacity.
The New Castle machine shop is structured to handle large forgings. The new FAT-HACO lathe is capable of machining forgings up to 866 inches long with 118 inches of swing. Forgings up to 200,000 pounds can be machined. There are 3 planar mills, the largest being a 300 horsepower milling machine with a 24 inch diameter main cutter and 12 inch diameter side cutter. There are also 2 engine lathes for rough machining shafts up to 580 inches long and 4 band saws able to cut up to 60 inches. A torch cutter is used for cut to length operations as well as pattern cutting.