forged fittings

Greg Sewell
Forgings is one
of Australia’s
largest forging
operations

Greg Sewell Forgings

A universal forge
that manufactures
& supplies to
local & export
markets

gs forgings australia

Forgings Manufacturing

OVER 85 YEARS OF CUSTOM FORGING AND MACHINING

Closed-die and Upset Forging, Threading, Hot Bending and CNC Machining for Construction, Mining, Energy, Transport, Defence, Rail and Agriculture.

Standard and Special Fastners, Bespoke Hot-Forged Steel Products and Fabrications of the Highest Calibre

Standard and Special Fastners, Bespoke Hot-Forged Steel Products and Fabrications of the Highest Calibre

With one of the most experienced and highest level teams in Australia, Greg Sewell Forging is Australia’s specialist in custom-made forgings and fittings. Not just fabrication and manufacturing, our dedicated team of forging experts can provide on-the-spot engineering solutions and advice from metal grades to product design and optimal process.

When quality, durability, and reliability are the most important considerations, choose local forging. Whether you need fast turnaround and complex metalwork, or high volume, continuous production our machining and forging capabilities are of the highest quality.

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Computer-Aided Design and Manufacturing

Computer-Aided Design and Manufacturing

GS Forgings’ capabilities extend across the complete manufacturing process. We prepare our own CAD drawings and design all of our own forging dies in-house. This allows us to offer the level of precision that we do, and enable complete flexibility for custom solutions and parts. We also employ Computer Aided Manufacturing to produce dies quickly and to incredibly tight tolerances.

Low Volume Single-Run Production to High Volume Continuous Production

Low Volume Single-Run Production to High Volume Continuous Production

All of our components and tooling are designed and manufactured right here in-house by an expert team. Our design and development capabilities are fuelled by innovation and an industry-leading approach to tooling and process efficiency.

By offering a complete end to end service, from design to delivery of components ready for installation, we’re able to keep our pricing and delivery times highly competitive.

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High Quality and Rigorous Testing

High Quality and Rigorous Testing

Greg Sewell Forgings is accredited to the ISO 9001 Quality Management System, which itself is subject to regular third party audits. This level of quality assurance is further supported by our own continuous updates and improvements of QA Procedures, Work Instructions and Methods.

Accreditation at this level demands that all products made at GSF must be compliant or exceed the requirements of National and International Standards.

Over and above our internal QA inspections and testing, we also employ independent NATA (National Association of Testing Authorities)-endorsed laboratories to perform both destructive and non-destructive testing, as agreed with each customer.

Such testing may include macro-etch testing of the raw material, mechanical tensile and impact testing, as well as Ultrasonic Testing and Magnetic Particle Inspection.

This added layer of external inspection and testing provides independent & objective evidence of compliance to the relevant standards applicable to each group of forgings or fabrications.

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Manufacturing Capabilities

Greg Sewell Forgings employs a wide range of metalworking processes to deliver the most ideal components for your particular application. From hot forging, forged fabrication, CNC machining to testing, we offer solutions to your industrial problems. 

Specifically, GS Forgings utilises a number of manufacturing processes to produce parts, including;

Closed-Die Hammer Forging
Closed-Die Hammer Forging

Our closed-die forging produces shapes from malleable steel materials using dies and mechanical, hydraulic or drop hammers.

Horizontal Upset Forging
Horizontal Upset Forging

We have 10 upsetting forging machines which are capable of deforming metal under great pressure into high strength components.

Induction Heating
Induction Heating

Heat treatments include, annealing, case hardening, precipitation strengthening, tempering, carburising, normalising and quenching.

CNC Machining
CNC Machining

Our precision machining expertise enables us to create production processes to consistently deliver high-quality finished components.

Welding
Welding

Greg Sewell Forgings is able to perform mechanical and physical inspection and testing. We’re accredited to AS/NZS ISO 9001:2008.

Hot & Cold Bending
Hot & Cold Bending

Greg Sewell Forgings hot bending capability includes hot and cold bending of bar including reo bar, plates, custom and angle brackets.

General fabrication
General fabrication

Our fabrication services include welding, pressing, bending, cutting, punching, shotblasting, drilling, tapping, threading & machining.

Our extensive experience enables us to provide specialist advice and help refine processes to create higher quality products. An example of this includes parts that have been previously fabricated from multiple parts utilising welding and forge-welding techniques, often of different material grades.

We’ve been able to propose solutions in such examples, of a forged integral part – which involves no welding. This ensures the part is made from an even material grade, and benefits from all the advantages of forging, with no weak weld points or inconsistencies.

Similarly, by combining a forged part with CNC refining, a product is able to meet extremely strict tolerances while being as resistant as possible to fatigue and stress, resulting in the most durable part possible.

Advantages of Forging

01

The advantages of forging in manufacturing stem from what’s actually happening to the particle structure of the metal itself, and the consistency. In cast manufacturing, molten metal is poured into a shape – expelling the air previously occupying that space.

02

While casting is often the most cost effective way to create a part, and is suitable for many applications, the grain structure and improved purity of a forged part is why they’re suitable for high stress, critical applications.

03

Forging is done by heating raw steel to around 1200℃, then shaping it using forging machines. This shaping is generally done by pressing or hammering, i.e. applying great force to deform the raw material into the shape of the desired part.

04

In simple terms, when a part is created through forging methods, the internal grain structure follows the shape of the part – similar to a tree branch. In doing so, the grain flow is continuous and provides directional strength properties in the critical regions where the material undergoes deformation.

05

In the case of a casting, for example, the steel is melted in liquid form and poured into a mould of the desired shape. When the metal solidifies, the internal grain structure is randomly distributed, because the metal was fully melted in order to be poured into the mould.

06

This means that the grain flow has been disturbed, and the advantage of continuous grain flow has been lost. The grain flow properties of forgings are vital in fatigue loading conditions of safety-critical products. No other process can impart these directional properties like forging does.

forgings vs machining

Forging vs CNC

Two very different processes, forging and CNC machining are actually very complementary. By manufacturing an initial part through hot forging, grain structure and flow is preserved – resulting in a very strong component. The part can then be further refined to precise tolerances through CNC machining.

The end result is a part that is very strong, flexible and durable and within incredibly tight specifications. By utilising a range of techniques, we can also create complex parts in low volume, single runs or set up tooling and processes to facilitate high volume continuous production.

Forging and Solutions for Industry

From mining shutdowns, agricultural applications and specific, discreet defence manufacturing to historical bridge revival, GS Forgings serves a diverse range of industry in Australia and Internationally.

All of our components and tooling are designed, machined and manufactured in-house, giving us the ability to quickly and efficiently meet the needs of any industry or application. We’re highly experienced in producing components from hot forged, cold forged and machined steel, with the capabilities to machine and roll threads of all diameters to customer specifications.

tension rods

Industry Sectors That We Service

Greg Sewell Construction
Greg Sewell Construction
GS Forgings Mining crushing
GS Forgings Mining crushing
Greg Sewell Power
Greg Sewell Power
GS Forgings Rail transport
GS Forgings Rail transport
Greg Sewell Agriculture
Greg Sewell Agriculture
GS Forgings Defense
GS Forgings Defense
Greg Sewell Marine Forging
Greg Sewell Marine Forging
GS Forgings Fastener
GS Forgings Fastener
Water Industry GS Forgings
Water Industry GS Forgings
GS Forgings Towing Lifting
GS Forgings Towing Lifting

Local and Global Delivery

Wholly Australian owned and operated, GS Forgings is proud to deliver the highest quality products both locally and internationally. We’ve built a proven history of supplying Australian and international customers in a timely fashion and at competitive prices. 

Our skilled design and development team will engineer a solution to your problem whether you’re local or overseas, and our world class manufacturing team will deliver components to exact specifications.