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Stock Forged Steel Rods
              Original equipment forged steel rods are the next step up the
strength and reliability ladder. Detroit sourced OE forged rods begin
life as bars of carbon steel that are passed through a rolling die. The
rolling process compacts the molecular structure and establishes a
uniform, longitudinal grain flow. The bars are then heated to a
plasticized state, inserted into a female die and pressed into the near
final shape while a punch locates and knocks out the big end bore. In
doing this, the grain flow at the big end is redirected in a circular
pattern, like wood fibers surrounding a knot, and excellent
compressive / tensile strength results. Finally the rod is put through a
trimmer (that leaves the characteristic thick parting line on the beam),
the big end is severed and machined to create the cap, bolt surfaces
are spot faced, then final machining and sizing take place.                     

             But there are some drawbacks. When the forging hammer hits
the hot bar, heat transfers from the bar to the hammer causing a
phenomenon called de-carb (decarburization). Here, trace amounts of
the carbon in the steel migrate to the surface resulting in a rough
finish full of what metalurgists call "inclusions". An inclusion is
described as anything that interrupts the surface of the metal or a lack
of cleanliness (impurities) in the material. The effect of a surface
inclusion can be likened to a nick in a coat hanger. Bend it enough
times and the wire will fail, usually right at the nick. The rough surface
caused by de-carb affect the surface to a depth of 0.005 to 0.030 inch
and is packed with inclusion that are a breeding ground for cracks.
The old hot rodder's trick of grinding and polishing the beams is a
valid solution to this problem, though far too labor intensive to ever be
considered by Detroit.                                                                              

            When it comes to inclusion caused by impurities, Detroit's
need to control cost can result in purchases of bulk steel that may (or
may not) contain contaminants such as silicon that are not detected
during manufacture. Such impurities can interrupt the grain
boundaries between the parent molecules and lead to a fracture
minutes or years after th rod is first installed in an engine. It's a matter
of luck and what kind of abuse the flawed rod is subjected to.              

           With very few exceptions, weakest link in a stock forged rod is
the fastener system. The rod bolt is usually the most marginal
component. Simply upgrading from stock bolts to quality aftermarket
replacements can improve durability by 50%. Just be sure to have the
big end resized to restore concentricity any time the bolts are removed.
Stock forged steel rods are an economical choice that should be able
to handle one horsepower per cubic inch with quality fasteners and as
much as twice the factory rated output if the beams are polished.          
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