Upset Forging

At Greg Sewell Forgings upset forging is one of the methods we use to deliver quality, high strength components.

With Australia’s largest collection of operational upset forging machines, our expert team provides a formidable capacity for Greg Sewell Forgings to deliver cost-effective and high-quality products to service the most demanding industries.


Upset forging basics 

In general, the process of hot upset forging involves heating one end of a metal bar, which is then deformed into the shape of the desired forging geometry. This may be a simple hexagonal head of a bolt or a much more complex shape requiring multiple operations.


Upset forging process 

Upset forging involves holding pre-heated material between grooved dies, also known as ‘grip dies’. Pressure is then applied to the end of the bar in the direction of its axis. 

The heading tool upsets the end of the bar by displacing the heated metal within a cavity. This takes place on a horizontal plane – allowing one end of the piece to be deformed while the rest remains intact.

It is common to have several upsetting operations on one die set, forming the bar to its desired shape in stages.


Why upset forging?

Upset forging has a unique advantage over other methods – like casting and welding. By heating the metal in isolated areas, upset forging maintains the overall integrity of the component and optimises the grain flow properties. This makes it far superior to fabricated items of the same shape. 

For example, due to the unbroken grain flow, forging a long bolt with a hexagonal head would be far superior to the same item being fabricated by welding a hexagonal nut on the end of the bar. 

grain flow lines model

Greater strength. 

The grain flow of upset forged components is superior to many other forging processes. While heating and deformation takes place at one end of the bar, the integrity of the rest of the bar remains intact. As such, the upset forging manufacturing process ensures parts are engineered to withstand extreme force and resistance.



Upset forging can achieve very long pieces with one or even both ends being manipulated.

It can also result in the gathering of large amounts of volume from the same bar, which can be used as the final finished product, or it can serve as a pre-forming operation for further forging in a drop hammer or a press.


Efficient and cost-effective. 

Heating parts locally means less energy is spent forging and tooling the entire workpiece. This saves energy and is better for the environment. 


Saves on materials and costs. 

At Greg Sewell Forgings our focus on expert design and precision tooling means we have the ability to achieve tight tolerances – and produce near-net pieces with minimal machining required. This translates into a huge cost savings for our customers. 

Metals are used in upset forging

Upset forged components are made from a variety of different metals. Depending on the desired shape and final performance properties, different metals are used to form the initial workpiece. At Greg Sewell Forgings, our bar stock includes:

  • Carbon steel
  • Carbon alloy steel
  • Stainless steel
  • Aluminium
  • Super alloys
gs forgings t bolts

Upset forging industry applications

Our competitive upset forging operations are used to forge high strength components for multiple different industries:

Choose Greg Sewell Forgings

Do you need greater strength, longer durability at competitive prices? At GS Forgings, our team of in-house designers and engineers can guarantee the highest quality finish on all custom components from inner structure to exterior machining.

Have peace of mind knowing your forged components are designed using cutting-edge computer-aided design and manufacturing technologies. 

Choose GS forgings for stronger forged components: call our expert team today on +61 3 8301 1500 or contact us via email.