Forged parts Manufacturers online

Forged parts are important components in various industries, as the forging process gives them high strength, toughness and reliability.

Forging is a forming process in which metal is shaped into a desired form under heat and pressure. This process can be carried out either manually with a hammer and anvil or mechanically with presses and hammers.

Below you will find the materials, the processes and an overview of the use of forged parts and their advantages, as well as notes on any post-processing:

Commonly used materials:

Metals that can be deformed under the effect of pressure and heat without breaking or cracking. These metals generally have a high ductility (malleability), which makes them ideal for forging processes.

• Carbon steel: A very common forged metal used for a variety of applications. Carbon content affects hardness and forgeability. Low-alloy carbon steel is easier to forge than high-alloy steel.
  Applications: Tools, machine parts, axles, shafts, screws and bolts.
• Stainless steel: Contains chromium and nickel, which makes it corrosion-resistant and durable. Stainless steels are more difficult to forge due to their composition, but are still well suited for applications where corrosion protection is important.
  Applications: Components for the food and chemical industries, surgical instruments, aerospace components.
• Aluminum and aluminum alloys: Highly malleable, lightweight and corrosion resistant. Due to its easy formability and light weight, aluminum is often used in the automotive, aerospace and construction industries.
  Applications: Lightweight components, automotive parts, aerospace structural components, heat sinks.
• 6061 Aluminum Alloy: One of the most commonly forged aluminum alloys, offering a good combination of strength, forgeability and corrosion resistance.
• Copper: One of the easiest metals to forge. It has high ductility and conductivity, making it particularly suitable for electrical and thermal applications.
  Applications: Electrical wiring, piping, fittings, art objects.
• Bronze (copper-tin alloy): Bronze is corrosion resistant and relatively easy to forge. It is often used in marine applications, for instruments and for decorative purposes.
• Brass (copper-zinc alloy): Brass is also easy to forge and is characterized by good corrosion resistance and visual appeal.
  Applications: Fittings, valves, musical instruments, decorative items.
• Titanium and titanium alloys: Titanium is more difficult to forge than steel or aluminum, but it offers an excellent combination of high strength, light weight and corrosion resistance. It is often used where strength combined with light weight is required.
  Applications: Aerospace industry, medical technology (e.g. implants), high-performance vehicles.
• Ti-6Al-4V: One of the most commonly used titanium alloys, known for its high strength and good workability.
• Magnesium and magnesium alloys: Very light and easy to forge, but more susceptible to corrosion. Magnesium is mainly used in the aerospace and automotive industries where weight savings are crucial.
  Applications: Lightweight components, vehicle components, electronic housings.
• Nickel: Due to its high resistance to corrosion and heat, nickel is often used in alloys suitable for extreme temperatures and environments. Nickel itself is harder to forge than other metals, but in alloyed form, such as Inconel or Monel, it is a popular choice for high temperature applications.
  Applications: Turbine blades, aerospace, chemical processing equipment.

Forging process:

Open-die forging:
This is where the metal is processed without special forming tools, usually using manual techniques or hydraulic presses.

Drop forging:
The metal is pressed into a pre-formed forming tool (die), creating precise and repeatable shapes.

Precision forging:
A variation of drop forging in which particularly precise tolerances and smooth surfaces are achieved.

Use of forged parts:

1. Automotive industry:
Crankshafts for engines, as they have to withstand high loads.
Forged parts give camshafts their durability and precision.
Wheel hubs, axles and steering parts have a high degree of stability and safety thanks to the use of forged parts.
Connecting rods connect pistons and crankshafts and have to withstand extreme forces.

2. Aerospace:
Turbine blades and disks used in aircraft turbines are forged as they have to withstand extreme temperatures and mechanical loads.
Forged structural components made of high-strength alloys for wings, fuselage structures and landing gear.

3. Power generation:
Gas turbines require forged parts for turbine components as they have to withstand high temperatures and pressures.
To ensure safety and reliability in power plants, shafts, flanges and pressure vessels are often forged.

4. Shipbuilding:
Ship propulsion shafts are usually forged as they have to withstand high torque forces.
Forged propeller shafts and bearings are preferred for their strength, durability and corrosion resistance in the maritime sector.

5. Mechanical engineering:
Highly stressed parts such as spindles and gears in machine tools are forged to maximize resilience.
Forged hydraulic pistons, cylinders and valve bodies are used for high-pressure applications in mechanical hydraulic systems

6. Construction industry:
High-strength tools such as chisels, hammers as well as pliers and clamps are classic forged parts.
Structural steel beams and connecting elements are forged for strong and safe structures in buildings and bridges.

7. Oil and gas industry:
Forgings are used in oil and gas production in the form of drill heads and valves due to their high resistance to extreme conditions.
Flanges and pipes are often forged to withstand the high pressures and temperatures in pipeline systems.

8. Agricultural machinery:
Forged parts in agricultural machinery, such as axles, power take-off shafts and plowshares, are extremely resilient and wear-resistant.
Important connecting elements and brackets in tractors and other agricultural machinery that have to withstand high dynamic forces are forged.

9. Railroad:
Forged railroad wheels and axles are highly resilient and are valued for their durability and resistance to extreme mechanical forces.
Brake shoes and other safety-related parts are produced by forging to ensure the safety and reliability of trains.

10. Medical technology:
Forged parts such as forceps, tweezers and scissors are used because they need to be precise and durable.
Some orthopaedic implants such as hip prostheses are made from forged titanium.

Advantages of forged parts:

• The forging process enhances the internal structures of the metal, resulting in greater strength and toughness.
• Compared to cast parts, forged parts have fewer cavities and material defects.
• Forged parts can better withstand high impacts and loads.
• The properties of forged parts make them more durable, especially in demanding applications.

Post-processing:

Forgings are often further processed after the forging process by machining, heat treatment or surface treatment to achieve the desired final dimensions and properties.

Forged parts are therefore indispensable in many industries, as they ensure the necessary performance and safety under extreme conditions.

Here is an overview of the most important points to consider when purchasing forgings:

When purchasing forgings, there are a variety of factors to consider to ensure that the parts meet specific requirements and standards.

• The right material is critical to the performance of the forged part. Depending on the application, you should ensure that the material is suitable for the expected loads, temperatures and environmental conditions. Commonly used materials are carbon steel, alloy steels, stainless steel, titanium and aluminum.
• In special environments, such as in the chemical or offshore industry, the corrosion resistance of the material is crucial.
• If the forged part is exposed to extreme temperatures, the material must have high heat resistance (e.g. for turbine components).
• Different processes such as open die forging, closed die forging or precision forging provide different properties. It should be checked which process is best suited to the desired requirements.
• After forging, parts are often heat-treated to further improve the mechanical properties. Pay attention to the type and quality of heat treatment (e.g. hardening, tempering) to ensure that the part has the required strength, hardness or toughness.
• Consider whether the forging requires a specific surface treatment, such as nitriding, galvanizing or other coating to increase durability or corrosion resistance.
• The dimensional tolerances of the forged parts must correspond exactly to the requirements of your application. This is particularly important for safety-critical applications.
• Check that the surface finish meets the requirements, especially in applications where the surface plays a role in function or aesthetics.
• Check the requirements for tensile strength, hardness, toughness and fatigue resistance of the forging required for your application.
• Ask for material certificates (e.g. EN 10204 3.1 or 3.2) to ensure that the material and production meet the applicable standards.
• Ensure that the manufacturer works according to internationally recognized standards such as ISO 9001, ISO 14001 or specific industry standards (e.g. DIN, ASTM).
• Important mechanical and chemical tests such as tensile tests, hardness tests, non-destructive tests (e.g. ultrasonic testing, X-ray testing) should be documented.
• Choose a supplier with extensive experience in forging parts for your specific industry. An experienced supplier can often give better advice on material selection and manufacturing processes.
• Pay attention to the supplier's ability to deliver the parts on time and to the agreed specifications. References or reviews from previous customers can be helpful here.
• Check that the supplier has the capacity and technology to produce the required quantity of forgings to the desired quality.
• Price should not be the only deciding factor, as high-quality forgings are often more cost-effective in the long term. Consider the life, maintenance requirements and reliability of the parts.
• Some suppliers have minimum order quantities, which can lead to higher costs for smaller projects.
• For regular orders, it can make sense to negotiate long-term supply contracts to minimize price fluctuations and ensure stable delivery times.
• In safety-relevant industries such as aerospace, automotive or power generation, quality and reliability requirements should be particularly high. Stricter testing and certification of parts is necessary here.
• For applications in harsh environments (e.g. underwater, in the desert or in highly corrosive environments), you should ensure that the forgings meet the specific environmental requirements.
• Check availability and delivery times with the manufacturer to avoid bottlenecks or delays in the production process.
• Forgings should be stored under suitable conditions to avoid corrosion or damage before installation. Make sure that the supplier provides suitable packaging and protective measures.

When purchasing forgings, focus on a combination of material quality, manufacturing process, precise technical specifications and the selection of an experienced supplier. Cost and availability are also important factors, but should not outweigh quality and suitability for the application.

Forgings can be purchased from a variety of suppliers. Comprehensive information about manufacturers and suppliers of Forged parts from all over the world can be found on Exportpages.