Closed die metal forging creates custom forged shapes that incorporate strength, leak-resistance and superior surface conditions at a price that fits your budget. By utilizing our closed die metal forging capabilities, we can create a precise replica of your design that can be produced repetitively and have close tolerances. Closed Die Forging is an inexpensive and efficient way to manufacture metal parts with numerous types of metals, depending on the application.
We can take any design and metal and turn it into a metal component through our closed die metal forging capabilities. Our closed die forging techniques allow us to create forged metal parts for many industries including:
Closed die forging is the process that metal is placed in a die resembling a mold attached to an anvil. Usually the hammer die is shaped as well. The hammer is then dropped on the workpiece causing the metal to flow and fill the die cavities. The hammer makes contact repeatedly within milliseconds. Depending on the size and complexity of the part the hammer may drop multiple times in a series of quick successions. The excess metal that is squeezed out of the die cavities is referred to as flashing. The flash cools more rapidly than the rest of the material and the flash is usually stronger than the metal in the die so it helps prevent more flash from forming. The flash also forces the metal to completely fill the die cavity and after forging the flash is removed.
In commercial closed die forging, the workpiece is usually moved through a series of cavities in a die to get from ingot form to the final form. The first impression is used to distribute the metal into the rough shape in accordance to the material needed later in the cavities. This impression is called an edging or fullering or bending impression. The cavities after this are called blocking cavities in which the piece is worked into a shape that more closely looks like the final product. These different stages usually give the workpiece generous bends and large fillets. The final shape is forged in a finisher or final cavity. If there is only a short run of the parts then it may be more economical to forgo the final impression cavity and instead machine the part.
While closed die forging is applied for almost all the metal materials, in actual production, only part of the materials are used for the different characteristics. The material used is one of the main factors that affect the cost of the forgings. Let’s take a look at some of the common materials used in closed die forgings.
When it comes to closed die forging, steel is by far the most common material used. Alloy steel, carbon steel, and stainless steel are all used depending on what the forging is used for. Stainless steel material is often used for components that require corrosion resistance and rust resistance. Alloy steel and carbon steel are the most widely used in closed die forging process for its competitive price and easy deformation.
Aluminum is popular due to its low density, high strength, and easy machining. It is widely used in closed die forging process especially for the automotive and aerospace industries. Although it is commonly used in the aerospace and automotive industries, it is a challenge for domestic forging due to the fact that it is easily deformed after forging.But heat treatment can help to improve the hardness and other properties.
Copper or brass is also commonly used in closed die forging, which is the most expensive of the three materials that we have discussed. Copper forging or brass forging is most commonly used for valve and pump fittings.
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