Forging is known as one of the oldest metal working processes and is still today considered the most effective. Traditionally performed using a hammer and anvil by a blacksmith, forging has evolved over the years to meet the demands of the modern engineering industry. While there are many variations of forging—each with their own distinct advantages—most involve heating the workpiece to very high temperatures to facilitate these shaping processes.
Compared to casting or other metalworking techniques, forging yields the most desirable physical characteristics—including a very high degree of tensile strength at a competitive price-point. Since the material is never melted, the compressive forces applied during the forging process force the grain to follow the flow of the finished product. This creates components that are much stronger than machined and casted counterparts.
Forging includes a range of different processes, typically grouped into 3 main areas – drawn out, upset and closed die hammer forging – each bringing its own benefits. The main advantages of forging include:
Stronger parts – as the metal is shaped during the forging process its grain texture deforms, refining and redirecting to follow the general shape of the part. This results in continuous texture variation throughout the part, producing improved strength characteristics and impact resistance.
Cost saving – compared to casting and fabrication, forging is a more cost-effective process when considering the costs incurred during the overall product lifecycle.
Reliability and longevity – forging is ideal for applications where reliability of each part is critical. The structural reliability of forged parts makes them trusted across a range of sectors.
Versatile design – forging can produce a diverse range of parts, from ring configurations, shaft and simple bar to specialised shapes. With a production capacity of up to 400kg, Brockhouse can deliver quality parts both small and large scale.
Forging can also prevent common defects found in casted parts. When casting, it is very common for a percentage of the parts to have unacceptable levels of porosity, shrinkage, or even voids. These issues can often lead to having to scrap near fully machined cast parts, therefore wasting valuable machining time. None of these problems can occur with forging as the material is never melted and reformed.
Brockhouse has over a century of forging history, servicing a comprehensive range of industries and delivering high quality forging solutions to meet specific customer needs. Our forgings can be found across the world, providing critical support for even the most demanding industries.
For more information or for a bespoke quotation please contact our team today.