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10 Drop forging cells online producing closed die formed components up to 75KG net weight and in specialist materials on request.
Drop forging is used to produce more complex forging shapes.
A combination of pre-form and closed-die tooling is used to align grain flow.
We have the ability to forge a wide range of ferrous and non-ferrous materials ranging from standard carbon & alloy steels, duplex, super duplex, nickel superalloys, and other non-ferrous alloys.
Our drop forging process is fully supported by our other internal manufacturing processes. Component design, forging feasibility and optimisation through CAD modeling and simulation, in-house tool room for quick turnaround of dies, in-house machine shop for proof or finished machined components.
The Benefits of Drop Forging
The drop forging process improves the strength of the metal by aligning the grain along the lines of potential stress, which cannot be achieved through casting, machining, or fabrication.
These types of drop-forged components are used by our customers in agriculture, transportation, defence, mining, forestry, medical and other industries.
Aligned Grain Flow Explained
Directional alignment through the forging process has been deliberately oriented in a direction requiring maximum strength. This also yields ductility and resistance to impact and fatigue.
Unidirectional grain flow has been cut when changing contour, exposing grain ends. This renders the material more liable to fatigue and more sensitive to stress corrosion cracking.
No grain flow or directional strength is achieved through the casting process.
The Drop Forging Process
The Drop Forging Process also referred to as Closed Die Forging, is a process that manipulates a heated metal bar, pre-form shape, or billet within the wall cavity of two dies.
This process is also referred to as impression die forging.
The impression for the forging can be in either die or divided between a top and bottom die, as shown in our illustration.
During this process, the material grain structure becomes compressed and aligned to the required component shape. This greatly improves strength and resilience.
Components manufactured using the drop forging process are stronger than their equivalent machined from solid or cast parts.