forgings

Forging is a metalworking process in which malleable metal is shaped by plastic deformation using localized compressive forces, typically applied by hammers, presses, or rollers. The workpiece is usually heated to increase ductility (hot forging) but can also be formed at room temperature (cold forging). Forging aligns the metal’s grain structure to follow the final shape, often improving strength and toughness compared with other forming methods.

Common forging techniques include open-die forging, in which the die does not enclose the workpiece; closed-die or impression-die forging, where the workpiece is shaped between two halves of a cavity; and precision forging, which uses closed dies to produce near-net shapes with tighter tolerances. Equipment ranges from power hammers and drop hammers to mechanical and hydraulic presses. Warm and hot forging conditions allow larger reductions in cross-section but require post-forging finishing.

Materials: Forging is used with a variety of metals, including carbon steel, alloy steel, stainless steel, aluminum, and titanium and their alloys. Forged parts are common in automotive components (axles, crankshafts, drive shafts), aerospace hardware, fasteners, hand tools, and industrial machinery. Cold forging, in particular, enables high production rates and excellent dimensional accuracy for fasteners and fittings.

Advantages and limitations: Forging can produce parts with improved grain flow and mechanical properties, increased fatigue resistance, and near-net shapes that reduce subsequent machining. Disadvantages include high tooling costs, limitations on certain complex geometries for some methods, and potential defects such as laps, die cracks, or folding if process control is inadequate. Forging has ancient origins in blacksmithing and remains a core method in modern manufacturing for durable metal components.