Closed-die forging, also known as impression die forging or drop forging, is a metal forming process where heated metal is hammered down between two dies repeatedly, forcing the metal into the shape of the die. For more complex shapes, this process is repeated multiple times with different dies to reach the desired final outcome.
At GS Forgings, closed-die forging is a core part of our metal forging capabilities and is used to produce a wide variety quality of products including:
- Crane hooks
- Towing Eyes
- Couplers & Turnbuckles
- Pole Line Hardware
With one of Australia’s highest quality collections of closed-die forging machines, the expert team at GS Forgings can deliver cost-effective and quality metal products to service the most demanding industries.
Need a product developed or wish to learn more about our fabrication and manufacturing capabilities? Please send us the details using the form provided or speak to one of our specialists on +61 3 8301 1500.
Benefits of closed-die forging
Closed-die forging is the preferred method of manufacturing for many different parts and industries, for a variety of reasons.
Versatile: Closed-die forging can be used to shape various metals and alloys such as aluminium, stainless steel, carbon steel, and titanium.
Strength: The closed-die process refines the inner grain structure of the metal, improving the strength and durability of the final product.
Minimal wastage: There is minimum wastage of raw material.
Complex shapes: Ability to produce complex shapes, intricate designs and shapes to exacting specifications.
Little to no machining: Closed-die forging produces a near-net-shape requiring minimal further processing. These benefits are not only seen in the uniformity of parts, but also in cost-reduction and efficiency.
Cost-effective and scalable repeatability: The closed-die forging process allows you to dial up your production capacity and take advantage of larger product runs at a reduced cost. As the external geometry of the piece is controlled by the impression of the forging dies, the same shape of product can be made as many times as required and by any machine operator.
Closed-die manufacturing capability
An essential part of the closed-die forgings manufacturing process is the machining of the die itself. This is a critical step as the quality of the die dictates the quality of the products produced.
The production of a closed-die can be expensive upfront but the cost can be easily offset by larger production runs where the efficiency of the closed-die forging process can save a large amount of time and effort replicating the end product.
GS Forgings has the capability to manufacture the closed-die at our in-house die manufacture centre and also execute the subsequent production run. Our forged closed-dies are designed using the latest state-of-the-art Creo and Hypermill CAD CAM system for an accurate and durable end product. Our modernised CAD CAM network provides our expert team with the tools required to develop cost-effective solutions for our customers.
If you’d like to know more about the process or cost/benefit of closed-die forging for your project, our team is happy to help.
The closed-die forging process in detail
The closed-die hot forging process makes use of two dies – a stationary die, and a moving die, which when struck together make the impression of the desired shape.
The top die is accelerated onto the heated metal forcing it to conform to the cavity between the two dies and take its shape. The excess metal, known as flash, is forced between the edges of the dies. This ‘squeezing out’ of excess metal results in a very uniform part.
The closed-die forging process is done either warm or hot, known as warm forging or hot forging respectively.
As the name suggests, hot forging is where the metal is heated to high temperatures before being forged. During the warm forging process, the metal is heated to a temperature range above the room temperature but below the recrystallisation temperature of the metal. Closed-die hot forging is the most widely used method in the forging industry.
Closed-die forging metals
A large variety of metals and alloys can be forged into a specific final shape. Some of the metals that can be easily forged are:
Steel: One of the most commonly used materials in the forging industry is steel. Popular for its superior malleability, different types of steel, such as alloy steel, tool steel, carbon steel, and stainless steel are used depending on what the forging is used for.
Aluminium: Extensively used in the automotive and aerospace sectors due to its low density, high strength, and easy machining, aluminium is widely used in closed forging processes.
Brass or copper: Copper or copper alloys like brass exhibit good plasticity and abrasion resistance and are easy to forge.
Industry Sectors That We Service
Greg Sewell Construction
GS Forgings Mining crushing
Greg Sewell Power
GS Forgings Rail transport
Greg Sewell Agriculture
GS Forgings Defense
Greg Sewell Marine Forging
GS Forgings Fastener
Water Industry GS Forgings
GS Forgings Towing Lifting
Need closed-die forging? Let us help.
GS Forgings uses the closed-die forging method to produce superior quality forgings in a vast array of sizes, final shapes, materials and finishes at our forging facilities. Our closed-die forgings are designed using the latest state-of-the-art Creo and Hypermill CAD CAM system. With one of the largest forging capacities in the southern hemisphere and over eight decades of experience, we are Australia’s specialists in closed-die steel forging, hot bending, upset forging, metal fabrication, threading and heat treatment.
To know more about our high-performance applications or to find out how we can provide custom forging solutions, please call us on (03) 8301 1500 and speak with one of our specialists or complete our contact form.