Upset forging services

Upset forging

At Greg Sewell Forgings, we use upset forging to create high strength components. With Australia’s largest collection of operational upset forging machines, our expert team can deliver cost-effective and high-quality products to service the most demanding industries.

Our upset forging process

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. The steps involved in our upset forging process are as follows: 

  1. Holding the pre-heated material between grooved dies
  2. Applying pressure to the end of the bar in the direction of its axis
  3. Displacing the heated metal within a cavity using a heading tool 
  4. The upsetting operation is repeated until the desired shape is achieved

Contact us for upset forging services

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.

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    Why choose upset forging for manufacturing?

    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. 

    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.

    Versatility

    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 & 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

    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. 

    Upset Forging

    Get in touch with our specialist now!

    Metals we use 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

    Why choose Greg Sewell Forgings?

    Do you need greater strength, longer durability at competitive prices? At Greg Sewell 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. Our trusted upset forging services are used to forge high strength components for a variety of industries including: 

    Choose Greg Sewell Forgings for stronger forged components and join the long list of national and international partners who have worked with us. Enquire about our packaging and shipping services to Australia and overseas, and find out more about how we can help you with your project.

    Contact us for upset forging services

    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.

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      Manufacturing capability

      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