From C95600 Castings to Forgings: IQS Engineering Solutions' Transformative Journey

Duranz, a popular material grade in the North American market, has long been utilized for clamps, connectors, and other electrical fittings. Traditionally, these fittings were manufactured as castings due to the perception that the grade C95600 was primarily a casting alloy. However, a challenge arose when a customer insisted that these parts could not be produced as forgings.

The Challenge:

Just a month before the onset of COVID-19, IQS Engineering Solutions was presented with a tight deadline and an engineering challenge: to convert Duranz fittings from castings to forgings. This posed a significant engineering dilemma but also an opportunity to innovate.

Our Approach:

With an unwavering commitment to excellence, IQS embarked on a comprehensive study of various copper alloys. Through rigorous research and experimentation, we identified a proprietary process capable of transforming castings into forgings. This innovative approach promised to address critical shortcomings associated with castings and unlock new possibilities for product design and performance.

The Benefits:

Enhanced Strength: By transitioning from castings to forgings, we achieved a remarkable increase in strength—double that of the original requirement. This enabled us to design more competitive and ergonomic products while reducing the overall material usage.

Improved Surface Finish: Unlike castings, which often exhibit inconsistent surface detailing, forgings provided unparalleled clarity and definition. This ensured that all markings and specifications were accurately rendered, meeting the stringent standards set by American regulations.

Overcoming Challenges:

The journey from concept to realization was not without obstacles. IQS dedicated nearly eight to ten months to a series of iterative trials, exploring various metallurgical compositions, heat treatment processes, and forging die designs. Through perseverance and ingenuity, we successfully developed a winning solution capable of producing C95600 forgings with precision and reliability.

Results and Impact:

To date, IQS Engineering Solutions has manufactured over 40 distinct components for our client, demonstrating our expertise and leadership in the industry. The conversion of C95600 castings into forgings stands as a testament to our commitment to innovation and excellence.

Conclusion:

At IQS Engineering Solutions, we are proud to lead the charge in transforming industry standards and exceeding customer expectations. Our success story with Duranz fittings showcases our ability to overcome challenges, innovate solutions, and deliver exceptional results.

Transform your manufacturing processes with IQS Engineering Solutions. Contact us today to explore how we can elevate your products and propel your business forward.

Note: This case study highlights just one example of our comprehensive capabilities in the electrical industry. We are dedicated to delivering excellence across a wide range of products and applications.