Electrical Upset Forging

We provide specialist electrical upset forging services, utilising high-precision resistance heating and hydraulic pressure to gather material at the end or mid-section of bars with unmatched volume and control.

By heating only the specific area required for deformation, we achieve massive localised material accumulation on relatively small-diameter bars, creating seamless, high-integrity components that outperform machined or welded alternatives.

We provide specialist electrical upset forging services, utilising high-precision resistance heating and hydraulic pressure to gather material at the end or mid-section of bars with unmatched volume and control. By heating only the specific area required for deformation, we achieve massive localised material accumulation on relatively small-diameter bars, creating seamless, high-integrity components that outperform machined or welded alternatives.

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The Electrical Upset Forging Process

Electrical Upset Forging is a high-precision process that combines electrical resistance heating with hydraulic pressure to gather significant volumes of material, often at a single end of a relatively small-diameter bar.

Clamping & Contact

The workpiece is secured within a ‘gripper’ while a hydraulic cylinder applies axial, compressive force. As the bar makes contact with the ‘anvil’, an electrical circuit is completed between the two electrodes.

Rapid Resistive Heating

A high-amperage, low-voltage current passes through the targeted section of the bar. The natural electrical resistance of the metal creates rapid, localised heating, bringing only the required area to the precise forging temperature.

Controlled Material Displacement

Once at temperature, the bar is driven into the anvil using controlled hydraulic force. This gradually "gathers" the material into the desired form. By precisely manipulating force, anvil position, and travel, we can control the volume and profile of the gather to create complex, bespoke geometries.

Versatility

This process is highly effective for bars up to 60mm in diameter and is compatible with a wide range of materials, including steel, stainless steel, and various exotic alloys.

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Why Choose Electrical Upsetting?

Massive Material Gathering

Capable of producing large-diameter flanges and heads on small-diameter bar stock, often achieving ratios far exceeding conventional upsetting.

Optimal Structural Integrity

Because the process maintains the material’s natural grain fibers, you receive a monobloc, one-piece component with strength characteristics superior to machined or welded assemblies.

Superior Energy Efficiency

Unlike batch furnace heating, our electrical resistance method heats only the local area required for deformation, significantly reducing energy consumption and carbon impact.

Material Utilisation

By forging "near-net" shapes, we minimise burr production and waste, allowing for significant cost savings, especially when working with high-value materials like stainless steel or exotic alloys.

Reduced Secondary Machining

Our ability to produce shapes closely aligned to the final component dimensions reduces the time and cost required for subsequent CNC turning and finishing.

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Precision, Sustainability, and Reliability