Forging is a process that gives metals their desirable shape so as to use them effectively in machine components. It begins with heating the metals such as copper, aluminum, brass to a temperature where it is moldable and then using precision machine dies and mechanical processes to forge parts to a near net shape. The whole process results in parts which are virtually free of imperfections and pores which lend them superior strength and finish and make them ideal for cosmetic surface requirements. When compared with mold casting, forged products are 15 % more strong and the primary reason for that is it does not change the grain structure of the metal.
The choice for the metals depends on the ultimate use of the forged product. Metals with shiny surfaces such as brass and copper are used for bathroom accessories, utensils, architectural hardware, musical instruments, mechanical parts, and fasteners. This choice is also based on the relative malleability of these types of metals which greatly eases the process of casting due to low melting point.
Another most commonly used metal for forging is Aluminum which has a wide range of applications and not just for the reason that it is the most abundant metal on the planet. Aluminum offers so many great qualities that are desired to make different parts. It is soft, durable, light weight, generally corrosion resistant and highly malleable.
Three grades of Aluminum present. Aluminum 2014 is used in making parts for the heavy industries such as airplanes and truck frames. Another grade, Aluminum 7075 is used in high-grade aircrafts and other aerospace vehicles. Likewise, Aluminum 6061 is used in a wide variety of formations as the main part of an alloy and is used varyingly in different situations such as railroad cars, tank fittings, general structures, marine components and high pressure applications such as pipelines etc.
Suffice it to say, forging is one of the key elements of modern industrial revolution. Forging has many benefits.
In comparison to casting it is
- Stronger: Casting fails to obtain the strengthening effects of hot and cold working. Forging surpasses casting in providing superior strength that is assured part to part.
- More Reliable: Forged products are more reliable than its casting counterparts because in later, the defects occur in many forms while in former hot working refines grain patterns which imparts a higher tensile strength.
- Respond better to heat treatments: Forging offers much better responsible to heat treatments than castings because in castings alloy segregation may occur. To prevent that non-uniform heat treatment is required which falters with the straightness of the finished product.
In comparison to fabrications/Weldments, forgings are
- More consistent with better metallurgical properties. Forging are devoid of any internal void that may cause an unexpected failure of the part under stress.
- Forgings offer simple production and ensures better and more consistent quality through out.
If you are looking for a forge company, there are many options available just make sure you check the quality of the products and the after sales services that the company offers for a smooth operation.