Forged shafts and drive shafts up to 40 tonnes
Forged shafts up to 12 m long — from as-forged blank to ready-to-install drive shaft with documented testing.
A forged shaft transmits torque under alternating load — the most demanding duty a component can face. In forging, the stock is upset and drawn out so that the grain flow stays aligned with the shaft axis. That grain orientation is the reason forged shafts outperform parts machined from bar stock or cast blanks in fatigue strength.
We supply drive shafts, rotor shafts, crankshafts and gearbox shafts from 20 kg to 40 tonnes and up to 12,000 mm in length. Depending on your requirements as a rough-turned blank for your own production, or fully machined including fits, keyways, gearing and balancing. Ultrasonic testing to EN 10228-3 is standard.
Technical data
| Piece weight | 20 kg – 40 t |
|---|---|
| Length | up to 12,000 mm |
| Diameter | 80 – 1,200 mm |
| Process | Open-die forging (upset and drawn out) |
| Reduction ratio | typically 4:1 to 6:1 |
| Machining | Rough-turned, pre-machined or finished incl. balancing |
| Testing | UT to EN 10228-3, MT to EN 10228-1, mechanical testing |
These are typical manufacturing ranges within our supplier network. Larger dimensions and special materials on request — send us your drawing.
Materials
- C45 (1.0503)
- 42CrMo4 (1.7225)
- 34CrNiMo6 (1.6582)
- 30CrNiMo8 (1.6580)
- 1.4021 / 420
- 1.4462 duplex
Manufacturing and quality assurance
- Stock supplied as ingot or continuously cast bloom, with heat analysis documented before production starts.
- Upsetting and drawing out to a defined reduction ratio — decisive for core quality in shafts.
- Quenching and tempering to the agreed strength class, verified on prolongation test material forged with the part.
- Ultrasonic testing to EN 10228-3 over the full shaft length; acceptance class as agreed.
- Finishing with fits, keyways and balancing on request — you receive the shaft ready to install.
Typical applications
- Drive shafts for machinery and gearboxes
- Rotor shafts for generators and turbines
- Crankshafts for large engines and compressors
- Extruder and screw shafts
- Roll necks and drum shafts
- Marine and propeller shafts
Frequently asked questions
What is the maximum length for a forged shaft?
Up to 12,000 mm in one piece, at diameters from 80 to 1,200 mm. Longer shafts are realised as welded or flanged assemblies — we assess feasibility from your drawing.
Which material suits drive shafts?
For most drive shafts 42CrMo4 in the quenched and tempered condition is the most economical choice. For higher loads or large cross-sections we use 34CrNiMo6 or 30CrNiMo8, and in corrosive environments stainless grades such as 1.4021 or duplex 1.4462.
Is the shaft tested and documented?
Yes. Ultrasonic testing to EN 10228-3 over the full length is standard, supplemented by magnetic particle testing of machined surfaces plus tensile, impact and hardness testing. All results appear in the inspection certificate 3.1 to EN 10204.
Do you supply finished or as-forged?
Both. Many customers order rough-turned shafts and carry out final machining themselves. We equally supply fully machined shafts with fits, keyways, gearing and a balancing report.
How long does a forged shaft take?
Pre-machined, typically 10 to 12 weeks from release. Large shafts with extensive testing and finish machining take longer. If the grade is one we hold in stock — 42CrMo4 or a common carbon steel, for instance — the lead time shortens.
Request a quote for Forged shafts
Send us your drawing or specification. You get feedback on feasibility, material selection and an indicative price — from engineers, not from a call centre.
Send enquiry