Open Die Forging

There are three methods of forging a piece of metal into a desired shape. These are open die forging, closed die forging, and rolled ring forging—with their names offering a general depiction of what each type of custom forging method does. There are advantages to using each method, and many factors are considered in advance to determine which forging type is ideal for different jobs. When a part is forged correctly with the proper equipment and the project is overseen by a highly skilled staff, both open and closed die forging methods and rolled rings will all yield high quality parts.

Open die forging is the oldest method of metal working known to man. Also known as hand forging, smith forging, hammer forging, and flat-die forging, open die forging has considerably evolved over the span of hundreds of years as technology and machinery has advanced. This process uses two dies that, unlike in closed die forging, do not completely encase the material. The material is heated to the required temperature, and is placed in between a top die that is attached to a ram, and a bottom die that is attached to either a hammer, anvil or bolster on a press. Once the metal is in place, the dies are used to repeatedly and continuously hit or compress the metal in order to form it into a specific shape.

There are many advantages to forging a part in the open die process. The open die method tends to be more cost effective for low volume parts. Additionally, parts forged in this method can result in finer grain sizes and continuous grain flow, resulting in an overall stronger part. Another positive for open die forging is that it is versatile. Any forgeable metal can be forged in the open die method, but generally, steel alloys, copper alloys, brass, aluminumInconel 625Inconel 718and titanium alloys are all popular common choices.

Reasons why open die forging can be the preferred forging method for certain projects include:

  • Parts that are too large to be produced by other manufacturing methods
  • Parts that require mechanical properties that cannot be achieved by other metal forming methods
  • Orders that have a small quantity requirement that wouldn’t justify tooling costs
  • Orders that involve a short delivery requirement, and wouldn’t allow time to make proper tooling
 

Additionally, this method of forging can be used on parts like rings that have special mechanical requirements, or that may require warm work or cold work, or are too large to be produced on a ring rolling mill. Once a part is forged in this application, it is common to have the product machine finished to achieve a smooth exterior.

There are generally two main disadvantages to open die forging. The first is material consumption. While open die forging is ideal for larger parts, this method is limited in close tolerance applications because it is not suited to form more precise details. Another thing to consider with open die forging is that there is typically more machining required for finishing these products.

Applications of Open Die Forging

Weldaloy Specialty Forgings is a leading provider for open die forged parts. The open die process is best used on specifications that are generally considered uncomplicated. There are four categories of general shapes where open die forging is typically the preferred method. These four categories are cylindrical shapes, upset or pancake forgings, hollow forgings, and contour-type forgings. Some part shapes that that usually fall in the realm of open die forging include discs, step shafts, shafting, and bars.

We service many industries that rely on open die forged parts, and understand the various needs and demands our clients have. At Weldaloy, we listen to what our clients need in a forged part, and work closely with them to ensure their requirements are met.

At Weldaloy Specialty Forgings, we are committed to producing the best open die forged parts. We house a 2,000 lbs. ton press capable for larger projects, with the capability to forge a single part from 20 lbs. up to 6,000 lbs. We also have various hammers and a seamless ring rolling mill.

We have a wide selection of materials for your project, including aluminum alloys, titanium alloys, copper alloys, and nickel-based superalloys. Overseeing every part produced in our facilities is our expert staff of engineers, metallurgists, and quality control personnel.

 

Our open die forging process capabilities include:

Item Max OD Max Face Height Superalloys Titanium
Rolled Rings
72"
20"
~ 45" Max OD
~ 48" Max OD
Item Max OD Max Thickness Max Weight Superalloys Titanium
Flat Bar / Blocks
96"
30"
~ 6,000 LBS.
~ 12"
~ 24"
Item Max OD Max Length Superalloys Titanium
Cylinders / Sleeves
50"
40"
~ 20" Max OD
~ 36" Max OD
Item Max Diameter Max Weight Superalloys Titanium
Disks / Hubs / Special Shapes
96"
~ 6,000 LBS. APPROX.
~ 12" Max OD / Width
~ 20" Max OD / Width
Item Max Diameter Max Weight Superalloys Titanium
Round / Shafts
36"
~ 6,000 LBS.
~ 12" Max OD
~ 16" Max OD
Item Max Pressure Superalloys Titanium
Custom Die Press
2,000 Tons
~ 12" Max OD / Width
~ 16" Max OD / Width

*Please note: We might not be able to do  that meet our absolute max for OD/Width or weight. Please reach out to a sales member for more specifics on your project.

Let Weldaloy Specialty Forgings supply your open die forging needs! Send us an RFQ and discover the Weldaloy difference!

Closed Die

Rolled Rings

“The team at Weldaloy treats me as if they care for me as a person…”

Learn about our Services.

We’re here for you. We’re flexible and enjoy building long term relationships with our customers. For over 75 years, we’ve been providing industry leading companies services such as those listed.

Why Weldaloy

Why is Weldaloy Specialty Forgings the ideal partner for your open die forging partner? There are several key components that prove Weldaloy is the ideal for your business.

Our Process

Weldaloy Specialty Forgings strives to meet every expectation that our customers require, with quality work at every level of production—from RFQ to the order’s delivery. Our processes allow us to keep the customer at the center of everything we do, making them a vital member of our team!

Our Capabilities

Weldaloy Specialty Forgings has a wide range of capabilities for your most challenging job. Forging, heat treat, rolled rings and machining are just some of the services we offer. Our facilities span over 115,000 sq. ft. of office and manufacturing space that house a ring mill, a 2,000-ton press, and five drop hammers ranging from 2,000-4,000 lbs. We are continuously making updates to our facilities to expand our capabilities, and to ensure we continue to meet the demands of our clients.

Engineering Capabilities:

  • CAD/CAM system-
  • SolidWorks
  • FORGE Forging
  • Simulation Software
  • SOP for control of CNC
  • Machine Programs

 

Testing Capabilities:

  • Chemical composition analysis
  • Mechanical testing (tensile-yield-elongation)
  • NDT Testing (dye penetrant, UT, radiographic)
  • Hardness, Conductivity, & Grain Size Analysis

Our Team

When you work with Weldaloy Specialty Forgings, you have a whole team behind your order that ensures our work is meeting the required standard. Weldaloy employs a highly skilled team of metallurgists with aerospace industry experience for projects with specific grain size and direction requirements, and ensures that our finished products meet mechanical and other testing standards. Weldaloy also has a well-staffed team of engineers that oversee our production processes, and at every step of production, our team of Quality experts verifies that our products meet the standard.

We focus on the small details to make sure our customers are getting the best quality in our products!

Our Certifications

Weldaloy Specialty Forgings is committed to making sure our accreditations are always up to date, ensuring a culture of consistency and attention to detail.

Our qualifications include:

  • AS9100D
  • ISO 9001:2015
  • ITAR Compliant
  • DNV GL Approved

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