This work presents the results of a study on the application of electroslag welding (ESW) to the assembly of heavy preforms for forgings. The technique uses ESW to join two or more blocks or ingots to form a large piece for open-die forging. Results are presented describing a development programme to manufacture and test such forgings in SAE 1045 steel in relation to commercial qualification specifications for machinery shaft application. The finished forgings are found to pass all such quality standards by a good margin. The general applicability of the technique in the field of open-die forgings is also discussed.
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