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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)]
0.45 (1) 0.15 (0.006) 0.48 (0.018)
0.91 (2) 0.20 (0.008) 0.61 (0.024)
2.27 (5) 0.25 (0.010) 0.84 (0.033)
4.54 (10) 0.28 (0.011) 0.84 (0.033)
9.07 (20) 0.33 (0.013) 0.99 (0.039)
22.68 (50) 00.48 (0.019) 1.45 (0.057)
45.36 (100) 0.74 (0.029) 2.21 (0.087)

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.





Specifications  · Value Added Services  · Material Selection  · Forging Advantages

Specifications

Workable Metals

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

Forging Techniques

Closed Die Forging
Hammer Forging
Open Die Forging
Precision Ring Rolling

Weight Limits

Dependent upon the part configuration. We supply from below 1/2 oz up to 75 lbs & larger are available

Press Tonnage

Various size tonnage presses are used to forge parts. The press size is dependant on the alloy and size of the forging.

Order Quantity

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.

Compliances

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.

Quality Assurance

Chemistry Compliance
Elongation Testing
Full Dimensional Reports
Hardness Testing
Heat Treating
MTRs (Material Test Reports/Material Analysis reports)
Optical Comparator Measuring
Tensile Strength Testing

Applications

Archery risers and other parts of bows
Arms & Ammunition Products
Clamps
Crank Shaft
Decorative Faucets
Decorative Handles
Electrical & Electronic Parts
Fasteners
Fire Protection Parts
Gas Turbine Intakes
Gear Shaft
Lighting Products & Parts
Lock Hardware
Marine & Boat Parts
Motor parts
Pipe Parts
Plumbing Parts
Surgical Tools
Valves Housings & Stems
Window Hardware

Industries Served

Architectural
Bathroom
Door & Window
Fastener
Fire Prevention
Industrial OEM
Marine & Naval
Oil & Gas
Pump & Valve


Value Added Services

Logistics Services

Bar Coding
Blanket Orders with Scheduled Releases
JIT (Just In Time) Delivery & KANBAN.
Lean Manufacturing service is our expertise.
Shipping Logistics
Special Packaging
Trucking
Warehousing Services

Value-Added Services

Anodizing
Assembly
Coating
Drilling/Tapping
Grinding
Heat Treating
Machining
Masking and Plugging
Plating
Polishing

Coating Options

Anodizing
Black Oxide
Chem-Film/Chromate Conversion
Dry Film Lubricant
Galvanizing
Painting (Primer/Topcoat)
Phosphate Coating (Zinc, Iron, Manganese)

Plating Options

Chrome Plating
Electroless and Electro-Deposited Nickel Plating
Gold Plating
Silver Plating
Tin Plating
Zinc Plating

Other Finishing Options

Passivation
Shot Blast Finishing
Silk Screening


Material Selection

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 Ductility
High Electrical and Thermal Conductivity
Non-Magnetic Properties
Non-Sparking Characteristics
Outstanding Machinability
Superior Corrosion Resistance
Superior Polishing and Finishing Characteristics

Aluminum Forgings

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.

Aluminum Alloys

2014
2219
2618
5083
6061
7049
7050
7075
7175
And Others

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.


Forging Advantages

High Strength

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.

Leak Resistance

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.

Close Tolerances

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.


 MORE IMAGES 

·  Aluminum Forged Machined Part (Top and Bottom)

·  Aluminum Forged Part

·  Aluminum Forging and Machined Part

·  Aluminum Forgings

·  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 Lot

·  Forgings with Flash On Them

·  Gas Cap - Brass Forging

·  Gas Forged Cap

·  Gas Part - Brass Forging

·  Hammer 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

·  Ring Rolling

·  Simple Brass Forging

·  Steel Forgings

·  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


 DOWNLOADS 

Conversions of Fraction to Decimal
(PDF, 36KB)

Hardness Conversion Table
(PDF, 55KB)

Metal Weight Conversion Table
(PDF, 29KB)

Wire Gauge Chart
(PDF, 33KB)

Common Metric Equivalents
(PDF, 39KB)


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