Forging processes have many different types and are used in the creation of forged components with desired performance characteristics, shape, and strength. The basic processes are open-die forging, which uses two flat dies to create large and relatively simple components; and closed-die forging, which uses specifically shaped dies to produce complex parts with a very high degree of dimensional accuracy. Hot forging shapes metal using elevated temperature to enhance its ability to flow (ductility) and to reduce the amount of force to be applied (resistance). Cold forging processes are performed at room temperature to produce better surface finishes and achieve more precise dimensions. The precision of the component manufactured using precision forgings will require little or no cutting at a later stage due to being produced to near-net shape. Forging processes will be selected based upon component design, material properties, production volume, and mechanical properties to satisfy the customers’ needs within the industrial and automotive industries.
Material used in manufacturing process of forged components
To create strong, durable and highly resistant to harsh environments forged parts, multiple types of superior quality metals are used during the manufacturing phase. The typical combinations are carbon, alloy and stainless steel; aluminum; brass; copper; etc., and the selection depends on the individual physical/mechanical attributes of the material and the requirements of the use. Carbon and alloy steels are predominantly used for heavily used parts due to their high tensile strengths and ability to wear well under extreme conditions; whereas, stainless steel is selected when corrosion resistance is critical. Lightweight applications using aluminum are selected because Aluminum has an very good strength to weight ratio. Non-ferrous metals such as brass and copper are generally used in building electrical and / or precision parts. Many specialized industries also use titanium and nickel alloys because they have superb resistance to temperature extremes, excellent strength and a lengthy service life to provide an excellent performance in all automotive, industrial and engineering applications for forged parts.
Benefits of using forged components instead of cast components
Compared with castings, forged parts have many benefits that make this process more desirable for automotive, industrial and heavy engineering applications. Unlike castings, forged metals’ internal grain structures are refined when forged. This leads to much higher strength, toughness and fatigue and impact resistance than castings. Also, forgings usually have lower levels of internal defects (e.g., porosity and shrinkage) than castings; thus, forgings have higher reliability and lower long-term wear under high loads.
Forging components also tend to have better dimensional accuracy, wear resistance and load-capacity. Due to these advantages, they have become popular choices for important applications, including crankshafts, gears, shafts, and structural components, where durability, safety and consistent performance are necessary requirements.
Conclusion
The final thoughts on forging of components include the following. Selecting the appropriate forging process along with the correct material are critical to producing a quality forged component. Forging methods including open die forging, closed die forging and hot cold and precise dies use to create a strong forged component with the intended shape or configuration, along with the required strength for endurance over time. When creating forged components, only high quality materials, such as carbon steel or other alloys of both stainless steel or aluminum, should be used to ensure that their use will endure through out the harshest of conditions in which they have a good chance of being used.
Forged components give you a mechanical advantage over cast components by providing higher mechanical strength, continued improvement of grain structure, fewer defects and enhanced service life. Therefore, forged components are the better choice for applications requiring safety, performance and durability in demanding environments including automotive, industrial and engineering applications.
