What is Forging?
The forging technique has been used for centuries to create tough components, and durable mechanical parts that are superior to their cast-metal counterpart. It’s often used to make tools, weapons, and other items out of tough metals such as steel and iron. Basically, it involves reshaping a piece of metal while it’s super-heated to make it stronger and more durable than it would be in its natural state. Forging is an old practice but has been made more precise with modern technology – industrial forges can now produce items with improved accuracy, and in far less time than before.
Those looking to produce components of high quality should definitely consider the processes involved in forging before looking to alternative production methods.
Types of Forging
According to the temperature at which it is performed, the forging process is classified as: Hot forging, Cold forging and Warm forging.
1) Hot forging: Traditional or hot forging is a process where metal is shaped at a temperature above its melting point, typically around 1200 degrees Celsius. This process is typically used for metals that are difficult to weld or work with using traditional methods.
2) Cold forging: In this process, the metal is shaped at a temperature below its recrystallization temperature. This process is typically used for metals that are ductile or malleable such as aluminum or brass.
3) Warm forging: It is a process where metal is shaped at a temperature above its recrystallization temperature, but below its melting point. This process is typically used for metals that are easier to weld or work with using traditional methods.
- Open die forging – Used for large, complex parts that cannot be produced using other methods.
- Closed die forging – Suited for small, intricate parts with tight tolerances.
- Upset forging – Used to remove large amount of material from parts, such as Shafts and pipes.
- Impression die forging – In this process, a metal blank is placed in a die and then forged using a hammer or press.
Forging can be performed using a variety of methods, including hammering, pressing, and rolling. It allows for the creation of some of the strongest and most resilient components and parts. This process is done in several stages
Step 1: Die and Mold Production The first step of the forging process, is crafting the die, using a combination of lathing, and hammering. In the die, cavities are created, which will take on the shape of the final product. The die will be woven from steel, and then hardened to resist wear and tear over the course of multiple forging cycles.
Step 2: Forging Process Once the die has been created, a heated metal bar is placed into the die cavity. A hydraulic or mechanical hammer then applies pressure to the metal bar, pushing it into the desired shape. As the metal softens due to the heat, it is easily manipulated into the desired shape as the hammer drives it into the die cavity.
Step 3: Trimming and Finishing At this stage, any excess metal is trimmed away, and the forged item is ground to precision. This could involve the use of metal files, grinders, and other precision tools.
Step 4: Finishing Operations The fourth and final step of the forging process is heat treatment. During this step, the metal is reheated and then cooled to a satisfactory temperature, at which point tempering occurs. A metal tempering process is used to treat the metal, making it harder and increases the overall durability of the item.
The forging process is understandably complicated, requiring tedious work and highly skilled technicians to ensure that the product is of the highest quality.
Difference between Forging and Casting
| In forging, metal is heated and then worked with tools to create a desired shape. |
| Typically used for creating smaller objects |
| Quicker and cheaper process |
| Able to achieve complex shapes and intricate designs |
| Require additional finishing work. |
| Surface finish is rougher, more textured finish as a result of its forging |
| In this process, the molten metal is poured into a mold to create a desired shape. |
| Used for creating larger objects. |
| More labour- intensive and time consuming process |
| Require extra machining process to achieve desired geometry of any size and shape |
| Requires little to no finishing |
| Smoother and more precise finish |
MATERIALS
Zastata uses a variety of metals and alloys for forging process to produce various types of products and items. There are a variety of metals that can be used in the forging process, each with its own advantages and disadvantages. The kind of material used to forge the part mainly depends on its application and utilization.
The most common metals used in forging are carbon steel, alloy steel, tool steel, stainless steel. Other materials such as aluminium, magnesium, titanium, copper, nickel, and their respective alloys are also used.
Carbon steel is the most commonly used metal in forging. It is relatively inexpensive and has a high carbon content, which makes it strong and durable. However, carbon steel is also susceptible to rust and corrosion.
Alloy steel is a type of steel that contains other elements, such as manganese, chromium, or vanadium, in addition to carbon. These additional elements give alloy steel greater strength and resistance to wear and tear. However, alloy steel is more expensive than carbon steel.
Stainless steel contains chromium, which makes it resistant to rust and corrosion. Stainless steel is also less likely to stain or discolor than other types of steel. However, it is more expensive than carbon steel.
Copper alloys are often used in the production of items such as gears, bearings, and bearings due to their superior resistance to wear and tear. Similarly, brass is a malleable metal alloy that is deemed to have superior ductility.
Aluminum is a lightweight metal, that can be quickly and efficiently shaped when heated, which is often used in the forging process. It is strong and durable, but also susceptible to corrosion.
Titanium is a very strong metal that is resistant to corrosion. However, it is also very expensive.
Nickel alloys are a type of steel that contains nickel, which makes them resistant to corrosion. Nickel alloys are also strong and durable, but they are more expensive than carbon steel.
Tool steel is a type of steel that is designed for use in tools and machinery. It is extremely hard and durable, but also very expensive.
In addition to ferrous metals, non-ferrous metals such as tungsten, titanium, and magnesium are often used in the forging process. These metals are incredibly strong and durable, yet at the same time relatively lightweight. Due to these qualities, they are often used in the manufacture of high-performance components such as aerospace parts, engine valves, and turbine blades.
Zastata also performs premium Inspection methods and quality testing procedures which include
- Dimensional Inspection: This inspection method is used to check the dimensions of the forged component. This is done using CMM, callipers, micrometers, and other measuring instruments.
- Visual Inspection: This inspection method is used to check the surface of the forged component for defects, including looking for surface defects, such as chips, scratches, or any other deformities. This is done using a magnifying glass or microscope.
- Radiographic Inspection: This inspection method is used to check the internal structure of the forged component. This is done using X-rays or gamma rays to detect any hidden flaws.
- Ultrasonic Inspection: This inspection method is used to check the internal structure of the forged component. This is done using sound waves.
- Magnetic Particle Inspection: This inspection method is used to check the surface of the forged component for defects. This is done using magnetic particles.
- Penetrant Inspection: This inspection method is used to check the surface of the forged component for defects. This is done using a liquid penetrant.
By regularly inspecting parts and detecting any flaws prior to use, Zastata can ensure that their components meet the desired quality and safety standards and help them produce safe and reliable components for a variety of industries.
Quality Documentation
Zastata has good understanding and experience with Quality documentation like:
APQP – Advanced Product Quality Planning
FMEA – Failure Mode Effective Analysis
PPAP Level 3 – Production Part Approval Process
SPC – Statistical Process Control
MSA – Measurement System Analysis
Quality Certifications
We work with manufacturers who hold certifications like:
ISO 9001:2015 (Quality Management System)
ISO 14001:2015 (Environmental Management System)
ISO 45001:2018 (OH & SMS)
AS9100 Rev C (Aviation, Space and Defence)
ISO13485:2016 (Medical Devices)
IATF16949:2016 (Automotive Quality Management System)
OTHER TYPES OF FORGING
Whilst Pressure die casting is widely used casting method for high volume production, there are other casting methods which have their merits
OUR MANUFACTURER LOCATIONS
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
COUNTRIES WE EXPORT
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
UK
USA
AUS
Denmark
Germany
Canada
France
China
INDUSTRIES WE SERVE
Advantages:
- Capable of producing parts with superior mechanical properties, such as increased strength and toughness.
- Suitable for both Ferrous, Non-ferrous materials and a wide range of alloys.
- Forged parts can also be designed with complex shapes that would be difficult or impossible to produce using other manufacturing methods.
- Requires minimal material usage with high accuracy.
- Offers high levels of repeatability, i.e., this process allows the manufacturers to produce multiple components in one forging cycle.
Applications
Forging is a centuries-old process that has been used to create everything from tools and weapons to jewelry and art.
- Today, it is still an important manufacturing process for a wide variety of products, including car parts, aircraft components, and medical implants.
- Forging is used to create various parts for cars, including engine and transmission components, suspension parts, and wheels. In addition to the automotive industry, forging is also used extensively in the aerospace, construction, and oil and gas industries.
- It is also a common technique in weaponry and Armor production.
- Used in the production of high-performance custom wheels that are ideally used for high-speed race cars and off-road vehicles.
At Zastata, we have a long history of expertise in producing a wide variety of forged metal parts for various industries, such as aerospace, automobile, Medical, Industrial, chemical, oil and gas, and many more. Using a wide variety of forging materials and highly dependable manufacturers, a skilled crew of Engineers, we produce superior products that offer high performance.
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