Forging is one of the oldest and most trusted metalworking processes, used to shape metal using compressive forces. It enhances mechanical properties, refines grain structures, and eliminates defects, making forged components ideal for demanding applications such as aerospace, automotive, power generation, construction, and oil and gas.
This article outlines the process flow of forging and highlights the key characteristics of forgings, offering insight into why forged components are preferred in critical applications across industries.
sakysteel
Forging is a manufacturing process in which metal is shaped by hammering, pressing, or rolling. It can be performed at various temperatures—hot, warm, or cold—depending on the material and application.
The main objective of forging is to produce parts with high strength, toughness, and reliability. Unlike casting or machining, forging improves the internal structure of the material by aligning the grain flow with the shape of the part, resulting in enhanced mechanical properties.
Forging involves multiple steps, from raw material preparation to final finishing. Below is a detailed breakdown of the typical forging process flow:
Raw materials such as carbon steel, stainless steel, alloy steel, or non-ferrous metals are selected based on application requirements.
Materials are inspected for composition, cleanliness, and consistency.
The selected bar or billet is cut into appropriate lengths using shearing, sawing, or flame cutting.
The cut blanks are heated in a furnace to a temperature suitable for forging (typically 1100–1250°C for steel).
Uniform heating is essential to prevent internal stresses or cracking.
The heated material is roughly shaped using an open-die or press to prepare it for final forging.
This step helps distribute the material uniformly.
The metal is forged into the desired shape using either:
Open-die forging (free forging)
Closed-die forging (impression die forging)
Ring rolling
Upset forging
Forging is done using hammers, hydraulic presses, or screw presses.
Excess material (flash) is trimmed off using a trimming press or saw.
The forged parts are allowed to cool in a controlled manner to avoid thermal stresses.
Post-forging heat treatments such as annealing, normalizing, quenching, and tempering are applied to:
Improve mechanical properties
Relieve internal stress
Refine the grain structure
Scale and oxidation from the forging process are removed by:
Shot blasting
Pickling
Grinding
Dimensional and non-destructive tests (e.g., ultrasonic, magnetic particle) are conducted.
Mechanical testing (tensile, impact, hardness) is performed to ensure compliance.
Some forgings may undergo CNC machining, drilling, or grinding to meet final specifications.
Products are marked with batch numbers, specifications, and heat numbers.
Finished parts are packed for delivery with required documentation.
Forgings offer distinct advantages in strength, integrity, and performance compared to cast or machined parts. Below are the core characteristics:
High tensile strength, fatigue resistance, and impact toughness.
Ideal for parts subjected to dynamic or cyclic loads.
Grain structure aligns with part geometry, increasing durability and resistance to stress.
Forging eliminates internal voids, porosity, and inclusions common in casting.
Can absorb shock and deformation without cracking.
Useful in high-pressure or high-impact environments.
Forged parts often have smoother, more uniform surfaces than castings.
Especially in closed-die forging, where tolerances are tight and consistent.
Suitable for a wide range of materials: stainless steel, alloy steel, tool steel, aluminum, titanium, and copper.
High material utilization compared to machining from solid blocks.
Simple, large shapes like shafts, discs, and blocks.
More flexibility, but less dimensional accuracy.
Complex, net-shape components.
Higher tooling cost, better precision.
Performed at room temperature.
Results in excellent surface finish and dimensional control.
Increases ductility and reduces forging forces.
Widely used for tough materials like alloy steel.
Crankshafts
Connecting rods
Gears and gear blanks
Flanges and fittings
Valves and couplings
Aerospace brackets
Railway axles
Heavy-duty shafts
Forgings are essential wherever high strength and reliability are required under challenging operating conditions.
Automotive: Engine parts, axles, steering knuckles
Aerospace: Landing gear, turbine disks, airframe components
Oil & Gas: Flanges, valves, pressure vessel components
Construction: Tools, structural connectors
Mining and Heavy Machinery: Rollers, shafts, pins, and links
Power Generation: Turbine blades, generator shafts
Forging is critical in these sectors where safety, performance, and service life are non-negotiable.
At sakysteel, forged products are manufactured and tested to meet global standards such as:
ASTM A182 – Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings
EN 10222 – Steel forgings for pressure purposes
ASME B16.5 / B16.47 – Flanges
ISO 9001 – Quality Management
EN 10204 3.1 / 3.2 – Mill Test Certificates
We ensure full traceability, quality documentation, and third-party inspection support as required.
Forging remains one of the most reliable and effective metal forming processes, capable of producing high-strength parts with unmatched integrity. From shaft forgings in power plants to critical components in aircraft and chemical reactors, forged parts offer superior mechanical performance, consistency, and durability.
By understanding the forging process flow and the key characteristics of forgings, engineers and procurement professionals can make informed material choices for their specific applications.
For high-quality forgings, including stainless steel and alloy steel parts, trust sakysteel to deliver precision, performance, and peace of mind.