Technical

Welcome to the Technical section of the site, which is a working in progress area helping to link the production method with our production service offered. Below starts the discussion about casting or forging, we would welcome the opportunity to talk in person regarding your component requirements.

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Casting or a Forging?

  • Why choose a forging over a casting or evening machining the component from solid bar? There are many reasons why a particular production method might be suitable, usually the answer is attributed to one or more of the following areas:
    • Cost
    • The quantity required
    • Performance & strength required (forging generally gives superior strength)
      • The grain flow attributed to that of a casting or a forging will relate to its strength properties
    • Production lead time (& Production location)
    • The complexity of the shape
    • The size and weight of the part
    • The finished quality required
    • Tolerance (+/- allowable – Mission critical vs non mission critical)
    • Inspection testing and certification
    • Your organisations policy & local governance (i.e. preferring to work with ISO 9001, 14001, fair and ethical trade considerations)

Closed & Open die forging:

  •  “Closed-die forging” is whereby the metal is placed in a die (effectively a mold), which is attached to an anvil.  The hammer is then dropped on the work piece, causing the metal to flow and fill the die cavities.
  • “Open-die forging” is whereby a hammer strikes and deforms the work piece, which is placed on a stationary anvil. Open-die forging effectively does not enclose the work piece, the dies (usually flat surfaces that are in contact) allow the material to flow outwards – except where restricted by the dies (if not flat).

Hot & Cold die forging:

  • “Hot” – Most metal forging operations are carried out hot, due to the need to produce large amounts of deformation in the part, and the advantage of an increased ductility and reduced strength of the work material. Hot die forging also eliminates the problem of strain hardening the metal. In cases where it is desirable to create a favourable strain hardening of the part, cold die forging may be employed.
  • “Cold” – die forging, while requiring higher forces, will also produce greater surface finish and dimensional accuracy than hot die forging. Did you know – some specific metal forging processes are always performed cold, such as coining (precision stamping to create sufficiently high stress to the surface a work piece – the term coming from the initial use of the process to manufacture coins).

Castings:

  • “Casting” in it basic form is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is removed from the mold to complete the process
  • There are numerous types of casting, for steel castings the main processes referred to are:
    • Die Casting
    • Investment casting (lost-wax casting)
    • Sand casting.

Our Technical section aims to link the production method with our production services.

Please call or email in the meantime to discuss further.