Induction Hardening

ECG has state-of-the-art induction hardening capabilities for crankshafts up to 320mm bore x 8-meters in overall length. ECG has the capability to control processes to produce hardened undercut fillets as necessary.

Vertical Gas Nitrider

ECG is the only crankshaft manufacturer in the world with vertical gas nitriding capabilities for cranks up to 8-meters in overall length. We have four large vessels capable of handling seven large crankshafts per furance load. State-of-the-art ammonia burn-off units were installed in 2009. Additionally, ECG made investments into the primary crankshaft elevator system.

Ion Nitride

ECG routinely Ion Nitrides pump and compressor crankshafts for various OEM's. Non-critical surfaces are masked to insure only the required areas are case hardened. ECG provides test samples to insure each load is correctly tested to the customer's specification.

Crank Roughing Mills

ECG has world-class crank roughing mills for cranks from 3-meters to 12-meters with weights up to 40 tons. ECG has a combination of both external wheel and internal wheel machines that provide nearly unlimited capacity on large crankshaft semi-finishing. Since 2004, ECG has rebuilt and modernized 5 mills and purchased a new internal roughing machine.

ECG forging and heat treating is impressive with continuous grain flow crankshafts up to 700mm circumference produced using state-of-the-art controls and processes including Heating Simulation. ECG has invested in modern power supplies and induction coils to eliminate variation in the forging process.

ECG has a significant induction heating simulation to insure sound practices at the forging press. We also harness the same technology by using the latest Forging Simulation. ECG is able to simulate the forging process in advance of actually forging a part to insure we produce a forging correctly the first time.

On the open-die forging side of the business, we have a unique CLEAN STEEL PROCESS combining our ultra-clean steel and open-die forging process to produce large one-of-a-kind crankshafts for OEM's around the world. The entire open-die process expanded with the development of a 77-ton ingot, 5000-ton open-die press and a 12-meter long twister to place the throw sets into the proper angularity.

ECG has a patented SURFACE PEENING process for placing the surface of a crankshaft under compression. This process allows for increased strength and resistance to fatigue. Other treatments include ROLLER HARDENING of fillets. This process is able to also target the fillets and improve the effectiveness of both conventional and surface treatments.

ECG also utilizes the latest CAM TECHNOLOGIES to allow for ultimate flexibility in the machine shop. We perform critical VERIFICATION on critical processes to insure we avoid collisions or programming errors.

We have participated in worldwide forging expositions where ECG has presented papers detailing our expertise on various subjects such as ECG Twisted Test Block. In addition, we also presented the attached paper on ideal crankshaft materials at the International Forge Masters Conference IFM 2008 Ellwood Crankshaft Paper.