Drop forgings Manufacturers online

Drop forgings are forgings that are produced using a process called drop forging or die forming.

In this process, metal is shaped by localized compressive forces exerted by a hammer or press. This process is characterized by the use of dies that determine the desired shape of the finished part.

Below you will find an overview of the process, the most commonly used materials and an overview of the use of drop forged parts and their advantages, as well as notes on post-processing steps:

Overview of the process:

• Heating: The metal workpiece is heated to a high temperature to make it malleable.
• Forging: The heated metal is placed in a die and worked with high-pressure blows or continuous pressure through a hammer or press. The metal fills the cavity of the die and takes on its shape.
• Deburring: excess metal, known as flash, is cut off the forging.
• Cooling: The forging is cooled, sometimes with controlled cooling processes, to achieve specific material properties.
• Finishing: Additional machining or finishing processes may be applied to achieve precise dimensions or surface qualities.

Materials used:

Metals that can be deformed under the effect of pressure and heat without breaking or cracking. These metals usually 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.

Use of drop forgings:

1. Automotive industry:
Drop forgings are used for crankshafts that must withstand high loads and dynamic forces in the engine.
Connecting rods connect the piston to the crankshaft and are exposed to strong forces, which is why they are particularly resistant thanks to drop forging.
Axles and wheel hubs are important safety components in vehicles that have to withstand extreme loads.
Chassis and steering parts such as wishbones, tie rods and suspension strut mounts, which are used in the chassis system.

2. Aerospace:
Die-forged parts are used in aircraft turbines as they have to withstand extreme temperatures and high speeds.
Components that are forged for the wings, fuselage structures and landing gear of aircraft must be lightweight and high-strength at the same time.
Components in the powertrain and drive systems of aircraft benefit from the high strength and reliability of drop forging.

3. Energy and power plant industry:
In power plants, both gas and steam turbines, drop forgings are used for turbine rotors and turbine blades, as they are high-strength and heat-resistant.
Generator shafts and flanges have to withstand the high torques and pressures in power generation plants.
Important components for pressure vessels and high-pressure pipes used in power generation, the oil and gas sector and the chemical industry have components made from drop forgings.

4. Shipbuilding:
Ship propulsion shafts are produced by drop forging to ensure the necessary strength and corrosion resistance for marine use.
Propellers and bearings must withstand extreme mechanical forces and the aggressive maritime environment.
Drop-forged parts are used for areas of hulls subject to particularly high stress, such as fasteners.

5. Mechanical engineering:
In mechanical engineering, drop-forged parts are used for gears, gear wheels, shafts and couplings to ensure high precision and load-bearing capacity.
Drop-forged hydraulic pistons, cylinders and valve housings are used for high-pressure applications in industrial hydraulic systems.
Forged spindles, guides and connections are used in high-performance machine tools.

6. Construction industry:
Hammers, chisels, bolts and other tools as well as fasteners are often made by drop forging as they have to withstand high stresses in the construction industry.
Drop-forged parts, such as connecting bolts and clamps, are used in heavy building structures such as bridges and high-rise buildings.
Forged steel beams and other structural components are used in load-bearing structures where high strength and stability are required.

7. Oil and gas industry:
Forged drill heads and tools are used in the oil and gas industry, where they must withstand extreme underground conditions.
Drop-forged parts in piping systems and valves are crucial for safety and tightness in high-pressure and high-temperature applications.
The high precision and durability of drop-forged parts is essential for pumps used in the production of oil and gas.

8. Agricultural machinery:
Drop-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.

9. Railroad:
Drop-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 made by drop forging to ensure the safety and reliability of trains.

10. Medical technology:
Precise and robust drop-forged parts such as forceps, tweezers and clamps are used in surgery.
Some joint and bone implants, such as hip and knee prostheses, are made from drop-forged titanium alloys to provide high biocompatibility and strength.

Advantages of drop-forged parts:

• The compacted material structure created by closed-die forging results in higher strength and toughness of the parts.
• As the metal is forged in closed dies, drop forgings are very precise and dimensionally accurate in their shape.
• Because dies can be used over and over again, drop forgings offer consistent quality and exact repeatability.
• Control over the forging process minimizes defects such as porosity or blowholes that can occur in other manufacturing processes.

Post-processing steps:

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

Drop forgings play a crucial role in numerous industries, especially where high strength, dimensional accuracy and reliability are required. Their applications range from the automotive and aerospace industries to power generation, construction, shipbuilding and medical technology. Due to their precise production and high mechanical properties, drop-forged parts are irreplaceable for many safety-critical and stress-intensive applications.

Below is an overview of the most important points that should be considered when purchasing drop-forged parts:

When purchasing die forgings, there are a number of factors that must be considered to ensure that the parts meet the desired requirements.

• Die forgings can be made from a variety of metals, such as carbon steel, alloy steel, stainless steel, aluminum, titanium and other alloys. The choice of material depends heavily on the application. For example, high-stress parts in the automotive or aerospace industries require high-strength steel or titanium, while stainless steel is preferred in corrosive environments.
• Ensure that the material has the required mechanical properties such as tensile strength, hardness, toughness and fatigue resistance.
• For applications in humid or corrosive environments, such as shipbuilding or the oil and gas industry, the corrosion resistance of the material is crucial.
• Drop forgings are characterized by high precision. Make sure that the manufacturer can meet the required tolerances, especially for critical components such as crankshafts or connecting rods in the automotive industry.
• Discuss the exact tolerances required for the function of the part with the supplier. Depending on the application, tight tolerances may be required, which can affect manufacturing costs.
• Ensure that the die forging process chosen is suitable for the requirements of your project. This could be hot or cold drop forging, depending on the type of metal and the final shape required.
• After the forging process, post-processing may be required, such as turning, milling, drilling or grinding to achieve the final shape and finish. These steps should be considered when evaluating suppliers and costs.
• Drop-forged parts are often heat-treated to improve their mechanical properties (e.g. hardening, tempering). Make sure that the manufacturer offers and verifiably carries out the required heat treatments.
• Depending on the application, the surface quality can be decisive. Drop-forged parts that are used in visible areas or in demanding mechanical environments often require finishing or surface treatment, such as grinding, polishing or coating.
• For parts exposed to harsh environments, additional surface treatment may be required, such as galvanizing, painting or nitriding to increase corrosion resistance.
• Ask for material certificates (e.g. in accordance with EN 10204 3.1 or 3.2) that document the chemical composition and mechanical properties of the materials used.
• Make sure that the manufacturer is certified according to international quality standards such as ISO 9001 or specific industry standards (e.g. IATF 16949 for the automotive industry or AS9100 for the aerospace industry).
• Make sure that the supplier offers non-destructive testing (e.g. ultrasonic or X-ray testing) as well as destructive testing (e.g. tensile tests, hardness tests) to ensure the quality of the forgings. Ask for the test certificates for your parts.
• Choose a supplier with proven experience in drop forging, especially in your specific application area. An experienced supplier can give better advice on material selection, the forging process and post-processing.
• Make sure that the supplier has the necessary capacity to produce the required quantity in the desired quality and within the required time frame.
• Check previous projects or customer references to ensure that the supplier will deliver on time and reliably.
• The choice of material has a significant impact on cost. High-strength alloys such as titanium are significantly more expensive than conventional steels. Therefore, consider whether the selected material is optimal for your application or whether more cost-effective alternatives are possible.
• The complexity of the forging process, the required post-processing and special surface treatments also influence the overall costs. It can be useful to compare different manufacturing technologies or methods to find the most cost-effective solution.
• Some suppliers offer volume discounts for larger quantities. If you have a long-term requirement for drop-forged parts, you can negotiate framework agreements or long-term supply agreements.
• Drop forged parts can have long lead times, especially when it comes to complex or large volume orders. It is important to clarify realistic delivery times with the supplier and allow for buffer times.
• Check that the supplier offers suitable packaging and transportation methods to protect the forgings from damage during transit. For larger or bulky parts, transportation can be more complex and expensive.
• Forgings, especially those made from materials susceptible to corrosion, must be stored under suitable conditions to maintain quality until use.
• When drop forgings are used in safety-critical areas such as aerospace, automotive or medical technology, stringent quality testing and certification is essential. These parts often have to meet strict regulatory requirements.
• For applications that are exposed to extreme temperatures, pressures or chemical environments (e.g. in the oil and gas industry), drop forgings must be specially designed to meet these requirements.

When purchasing die forgings, it is important to consider a variety of factors to ensure that the parts meet the specific requirements. In addition to material selection and precise adherence to dimensional tolerances, quality assurance, supplier selection and cost efficiency are also important. A thorough review of the technical requirements and working with an experienced supplier will help to procure high-quality drop forgings that are durable and reliable.

Die forgings can be purchased from various suppliers. Comprehensive information about manufacturers and suppliers of Die forgings from all over the world can be found on Exportpages.