Leverage the Strength and Durability of Metal Forgings for Your Industrial Design Needs

Whether prototyping machinery components or producing structural automotive parts at scale, metal forgings provide unparalleled strength for demanding applications. This guide explores how partnering with a forging expert opens possibilities for complex shapes through proprietary manufacturing processes.

An Introduction to Metal Forging Processes

Metal forgings are created by compressing or deforming heated metal stock into sophisticated predetermined shapes. Machinability, strength and fatigue life are improved compared to cast or machined alternatives. Common materials include carbon/alloy steels and specialty alloys like titanium and Inconel.

By outsourcing to industry-leading forging facilities, you gain access to heavy presses, specialized tooling and process knowledge to produce rugged, intricate custom forging parts once impossible to fabricate.

Selecting an Experienced Forging Manufacturer

Consider key capabilities like equipment, materials expertise, quality systems and more when partner selection:

Forging Capabilities

Inspect mechanical and hydraulic presses, die systems, heat-treating furnaces.

Materials Experience

Evaluate experience with required alloys, product certifications, metallurgical specifications.

Quality Management

ISO/AS9100 certification demonstrates aerospace-grade processes, documentation, inspections.

Finishing Options

Assess machining, heat-treating, cleansing, passivation to meet surface/dimensional needs.

Program Management

Validate project execution expertise for prototyping through high-volume production.

Core Metal Forging Manufacturing Processes

Top forging partners leverage sophisticated techniques including:

Open-Die Forging

Malleable stock is compressed in open-face dies to achieve basic shapes.

Closed-Die Forging

Matching-face dies impart precision dimensions, features in closed-cavities.

Upset Forging

Axial compression enlarges stock cross-sections to tight tolerances +/- 0.001".

Drop/Hammer Forging

Impact blowsform stock nubs to net-shape or near-net housings, flanges.

Isothermal Forging

Controlled heating maintains stock temperature for clean, defect-free results.

Industries Enhanced by Metal Forging

Given ability to fabricate rugged components in specialized alloys, key sectors include:

Oil/Gas

Forged valves, manifolds withstand pressures in offshore drilling equipment.

Aerospace

Landing gear, jet engine components leverage forgings' strength-to-weight ratios.

Industrial Machinery

Custom housings, frames form the backbone of durable fab machines.

Construction Vehicles

Axles, frame joints on excavators and bulldozers use high-strength forgings.

Tools/Hardware

Socket heads, linkages fabricated forgings serve mission-critical functions.

Partnering Advantages for Forging Development

Outsourcing forging manufacturing provides benefits including:

Process Optimization

Dedicated R&D and capability maximize materials' traits in forging designs.

Quality Management

Aerospace certifications ensure consistent, defect-free custom forging parts.

Equipment Investment

Leverage multi-million dollar automated forging lines without CapEx.

Production Flexibility

Scale volumes with existing capacity versus new factory buildouts.

Program Management

Engineers deliver prototypes through long production runs on schedule.

Partnering Requires Careful Planning and Execution

To ensure project success, consider:

Provide Thorough Designs

Early 3D models streamline development of optimized forging tooling.

Specify Materials

Discuss required alloys, treatments to procure optimally for your design.

Evaluate Tolerance Needs

Tight dimensions may impact tooling complexity and per-part pricing.

Use Stage-Gate Approvals

Sampling validates designs and prevents re-work prior to production.

Plan Communication

Status updates maintain alignment to delivery timelines and quality goals.