Hobbies And Interests
Impression Die Forging
Impression die forging -- also known as closed die forging -- is the process used to create three dimensional objects. There is virtually no limit to the product's size, varying from a few ounces to over twenty-five tons. The hot metal is shaped by being placed between two dies. Dies are basically two half-molds that are closed together. Simply put, the process is similar to a waffle iron closing onto batter. Impression die forging is used on materials such as steel, aluminum and titanium. The dies can create intricate designs in addition to "spherical shapes, block-like rectangular solids and disc-like configurations."
Cold Forging
Most forging is done at temperatures as hot as 2,300 degrees Fahrenheit. Cold forging, however, is done between room temperature and a few hundred degrees. Like impression die forging, the cold forging process also uses a closed die. This technique is applied to things like automotive parts that weigh up to ten pounds. Cold forging is used on materials such as carbon steels, stainless steels, brass, bronze and some aluminum alloys.
Open-Die Forging
Unlike its impression-die and cold-forging counterparts, open-die forging is done between two flat dies. This means that there is no pre-cut mold. Enormous amounts of metal can be forged with this technique, reaching sizes of over 200,000 pounds. In order to create the desired shape, the material is gradually manipulated with the flat dies. This is the method of choice for large shapes that require strong structural integrity. Open die forging is also very versatile, usable for almost any iron or non-iron alloys.
Seamless, Rolled-Ring Forging
Seamless, rolled-ring forging differs from other methods in that no dies are used. A round piece of material is taken, then a hole is punched through it to resemble a donut. The donut-shaped metal is twisted, squeezed and pounded into a thin ring that can be from a few inches to 30-feet in diameter. The end product can weigh from less than a pound 350,000 pounds. Critical industries, such as energy generation, mining and aerospace, all rely on components like these for use in construction. Seamless, rolled-ring forging is used on carbon alloys, steel, aluminum, copper and titanium.