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Custom Closed-Die Metal Forgings
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Custom Closed-Die Metal Forgings
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Impression-die forging is also called closed-die forging. In impression-die a heated hot billet is placed in one side of a die that resembles half of the impression of the part being forged and attached to the base of the forging press (also referred to as the anvil). The other half of the die is on the top portion of the forging press die plate holder (also referred to as the hammer head). This top part of the die, in the head, strokes downwards mating the two halves of the die. The hot metal billet now flows and fills the die cavities.
The top die is generally in contact with the workpiece for a very short period of time, on the scale of milliseconds.
Depending on the size and complexity of the part the top die may be stroked multiple times in quick succession to ensure that the part is forged to the exact dimensions. Excess metal is squeezed out of the die cavities, forming what is referred to as flash. The flash cools more rapidly than the rest of the material; this cool metal is stronger than the metal in the die so it helps prevent more flash from forming. This also forces the metal to completely fill the die cavity. After forging, the flash is removed in a clipping press with clipping/trimming dies.
Closed-die forging has been further improved in recent years through increased automation which includes electric induction heating, mechanical feeding, positioning and manipulation, and the direct heat treatment of parts after forging.
There are other variations of part formation that might be employed in closed-die forging. One method uses casting liquid metal to produce a forging preform. The casting is removed after it has solidified and while still hot it is then placed into a single cavity forging die and forged. The flash is then trimmed or clipped and if the metal requires it, the part is quench hardened.
Closed-die forging has a high initial cost due to the design and production of dies required to make working die cavities. However, it has low recurring costs for each part, meaning that forgings become more economical with more volume. This is one of the major reasons closed-die forgings are often used in the automotive and tool industry. Another reason forgings are common in these industrial sectors is because forgings generally have about a 20 percent higher strength-to-weight ratio compared to cast or machined parts of the same material.
The dimensional tolerances of a steel part produced using closed-die forging methods are outlined in the table below. It should be noted that the dimensions across the parting plane are affected by the closure of the dies and are therefore relative to die wear and the thickness of the final flash. Dimensions that are completely contained within a single die segment or half can be maintained at a significantly greater level of accuracy.
Dimensional tolerances for impression-die forgings of a steel part. These differ for brass and aluminum.
Mass [kg (lb)]
Minus Tolerance [mm (in)]
Plus Tolerance [mm (in)]
A lubricant is always used when forging to reduce friction and wear. It is also used to as a thermal barrier to restrict heat transfer from the workpiece to the die. Finally, the lubricant acts as a parting compound to prevent the part from sticking in one of the dies.
Being a one-stop shop for all custom metal forging, Deeco Metals offers cost effective forged components for a number of industries, including architectural, marine, plumbing, valves, pumps, oil & gas and other industrial applications and commercial products.
We provide different forging techniques, including closed and open die forging, hammer forging and also precision ring rolling. Using Lean Manufacturing techniques, our engineering experts excel in supplying forged components with quick turnarounds.
With capabilities to manufacture the forging tools in-house, we offer short lead times on new products and faster resolution of tooling issues on existing products. Most any production volume ranging from small batches to large production runs is not a problem for us.
Apart from forging components, we also offer a variety of secondary operations such as machining, polishing, plating, powder coating, anodizing, painting, and assembly.
KANBAN or Just In Time (JIT) delivery services are provided as well. Special packaging options are also provided for forged components. Expedited delivery service is also available.
Value Added Services
Aluminum Alloys, 6000 and 7000 series, others upon review
Brass C37700 is standard forging alloy used for brass forged parts
C11000 copper HC or ETP (High Conductivity or Electro Tough Pitch) - other coppers are available upon review
Copper Alloys - Many Brasses and bronzes are forgeable and available upon review
Stainless Steel Alloys 300 series, others upon review
Steel Alloys upon review
Closed Die Forging
Open Die Forging
Precision Ring Rolling
Dependent upon the part configuration. We supply from below 1/2 oz up to 75 lbs & larger are available
Various size tonnage presses are used to forge parts. The press size is dependant on the alloy and size of the forging.
Minimum quantities relative to the weight of the part (heavyweight-fewer parts per PO, lightweight-more parts per PO)
No limits on large production orders.
Typical Lead Time
Based upon material, profile and secondary operations, typically, samples for approval 5 to 6 wks ARO and production 10 to 12 wks after sample approval. Airfreight is also available for an expedited delivery.
All detailed specifications are on our web site or are available on request.
Our forgings meet ASTM B 283 Specs for copper alloys & ASTM or SAE specs for all other materials.
Full Dimensional Reports
MTRs (Material Test Reports/Material Analysis reports)
Optical Comparator Measuring
Tensile Strength Testing
Archery risers and other parts of bows
Arms & Ammunition Products
Electrical & Electronic Parts
Fire Protection Parts
Gas Turbine Intakes
Lighting Products & Parts
Marine & Boat Parts
Valves Housings & Stems
Door & Window
Marine & Naval
Oil & Gas
Pump & Valve
Value Added Services
Blanket Orders with Scheduled Releases
JIT (Just In Time) Delivery & KANBAN.
Lean Manufacturing service is our expertise.
Masking and Plugging
Dry Film Lubricant
Phosphate Coating (Zinc, Iron, Manganese)
Electroless and Electro-Deposited Nickel Plating
Other Finishing Options
Shot Blast Finishing
Copper, Brass & Bronze Forgings
Forgings of Copper, Brass and Bronze alloys offer a number of outstanding advantages over parts produced by other manufacturing processes. These advantages result from the inherent properties of copper and copper alloys plus additional improvements in mechanical and physical properties imparted by the forging process. Multiple coring is offered by Deeco Metals to reduce the metal and labor cost in a forged and machined part.
Copper, Brass and Bronze Forgings Features
Attractive Solid Colors - Not Just Surface
Excellent Joining and Plating Characteristics
High Electrical and Thermal Conductivity
Superior Corrosion Resistance
Superior Polishing and Finishing Characteristics
Aluminum Forgings are generally used in applications where the high integrity of the part is of utmost importance. They are used primarily for structural components such as the intake of Gas turbine engines where light weight is crucial. In automotive applications, forged components are commonly found at points of shock and stress. The aluminum components we manufacture range in weight from a few ounces to a few hundred pounds, and are forged into a wide variety of shapes and sizes with or without cores.
Stainless Steel & Alloy Steel Forgings
Stainless and Alloy Steel forgings are manufactured for use in various environments including offshore and land installations, chemical, petrochemical, food processing, medical tool & equipment industry, power generation, marine and general engineering. Stainless Steels are used in the low -pressure turbine (hot) section of gas turbines. Alloy Steels are used for various gas turbines components where high strength and wear characteristics are required.
In making a forging, the metal is worked twice under tremendous pressures. First during rod extrusion, drawing or rolling and then during forging. The double working under pressure, compacts the metal, and produces a very dense and refined grain or fiber structure. The tensile strength of the parts is thereby increased, and resistance to impact and abrasion is enhanced.
The dense non-porous forged metal permits the designer to specify thinner sections without the risk of leaks. Often, the thinner forged parts result in lighter weight and lower piece cost compared to other manufacturing processes.
A forging produced in a steel die with close tolerances offers several advantages. Overall part dimensions are held closer than in sand casting. Dimensions show minimum variation from part to part allowing for automatic chucking and handling in subsequent operations. The precise designs on the die surface can produce sharp impressions on the forging surface, which is normally not the case with other forming processes.
Low Overall Cost
Mass production of forged parts lends itself to maximum savings. However, smaller quantities of copper alloy forgings can also prove economical when specific design parameters must be met. These requirements include leak integrity, close tolerances, high strength with low weight, and non-symmetrical shape.
Aluminum Forged Machined Part (Top and Bottom)
Aluminum Forged Part
Aluminum Forging and Machined Part
Bearing Cage Forged Ring
Bearing Cage Forged Rough Rings
Bearing Cage Machined From Rings
Billet in Forging Die
Billet In Forging Press
Billet Upright in Forging Press
Bimetal Copper Aluminum Forging
Bimetal Forged Aluminum & Copper Clamp
Bimetal - Aluminum Copper Clamp
Bow Risers - Forged Aluminum in Crate
Bow Risers Forged in Aluminum
Bows Risers Forgings Packed in Crate
Brass Forged Parts
Brass Forging with Core
Coupling - Aluminum Forging
Gas Head - Forged and Machined
Golf - Brass Putter Head Forged
Valve - Forged Blank Aluminum
Brass Forgings Machined
Brass Forging Bar - Ready for Cutting Into Billets
Caps Forged Out of Brass
Clamp Electrical Parts
Clamps - Electric
Clamps - Forgings Unscrewed
Collars - Brass Forgings Machined
Electric Copper Contacts
Electrical Contact Forged in Copper
Electrical Copper Contact Forgings
Electrical Copper Part Forging
electrical Manganese Bronze Forged Stem
Eye Clamp - Brass Forging
Flange - Forged and Machined
Forgings with Flash On Them
Gas Cap - Brass Forging
Gas Forged Cap
Gas Part - Brass Forging
Handle - Brass Forgings with Flash
Handle - Removing Flash and Bending Operation
Handle Showing Flash
Handle Without Flash
Handles - Aluminum Forging Polished and Surface Treated
Handles for Door - Brass
Inspection Measuring with CMM
Key Blank - Forged Without Cleaning
Lever - Brass Forgings
Lock Body - Forged in Brass
Marine - Forged and Machined Part
Nut - Forged and Machined
Nuts Ready for Machining in Automatic Machine
Packed Machined Forgings
Pad Eye - Forged Steel and Stainless
Pad Eye - Stainless Forging Machined Polished
Simple Brass Forging
Valve Body Forged
Valve - Brass Part Forged and Machined
Valve Fitting - Brass Forging Blank
Valve Fitting - Brass Forging Blanks
Valve Forged With Cores
Valve Forging - Machined
Valve Forgings In Brass
Valve Fully Machined (Top & Bottom)
Valve - Forged Brass Parts
Valve Parts Machined From Forgings
Valve Stem Forged
Conversions of Fraction to Decimal
Hardness Conversion Table
Metal Weight Conversion Table
Wire Gauge Chart
Common Metric Equivalents
ISO 9001:2000 Compliant and Certified
10-16 Renee Place, Irvington, NJ 07111, USA www.deecometals.com
Phone: 1-800-272-7784 International: 1-973-373-0070 Fax: 1-800-220-6180 Email:
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