Closed die forgings by far are the largest type of forging produced. They accounted for over $5.8 billion of the $8 billion in revenue generated from custom forgings. The production of a closed die part requires the use of two or more dies, referred to as tooling.
These dies first must be manufactured with the predetermined profile of the part being produced. The material is heated up to its deformation temperature and is then pressed or hammered between these dies. The restriction of the metal flow inside the dies allows the production of parts that are more complex in shape than a part being produced by the open die process.
Additionally, this process allows for closer tolerances than those produced in open die. Relatively simple shapes can also be processed this way, but the decision is usually driven by economics and meeting some of the conditions listed below. Also, even though there are tooling charges associated to this process, these cost can be recovered quickly when certain conditions exist. Advantages of Open Die Forging 1. The production of parts that are "near net shape" reduces the amount of input material that goes into the product and offers cost savings on raw material.
2. In addition, by producing the "near net shape", the amount of machining required is greatly reduced over that of the open die process offering further savings per part 3. Here is the key; when you are in production and manufacture of "high volumes" of product, the cost of the tooling becomes relatively insignificant as it is amortized over all the parts produced. 4. The ability to make complex shapes with closer tolerances (as detailed above) You may find that the initial deliveries of the closed die parts are a little longer than in the open die process. Typically though, a blanket release schedule accompanies this process and delivery dates are set up well in advance giving peace of mind about delivery schedules.
The closed die forging process offers the same general advantage of all forging processes. Products will have mechanical properties which exhibit higher strength over other metalworking processes. As a result, when safety and reliability are issues for your parts or processes, closed die forged products should be considered. Industries that rely on closed die forged products include, but are not limited to Aerospace (including space exploration, commercial, industrial and private aircraft), Electronics including Semiconductor Process Equipment and OEM's and Machine shops who process parts for them. Most engineered metals and alloys can be forged through the conventional closed die process, including ferrous materials, like carbon and alloy steels, tool steels and stainless steel.
Also nonferrous materials of aluminum and copper alloys and certain titanium alloys can be forged in an impression die. Nonferrous alloys that are typically forged include, C10100 (OFE or Oxygen Free Electronic), C46400 (Naval Brass), C18200 (Chromium Copper), C70600 (Copper Nickel) and C18150 (Chromium Zirconium Copper).
Weldaloy Products Company specializes in the forging of specific nonferrous alloys. If you would like to learn more about open or closed die copper or nonferrous alloy forging and how they can work for your industry or application, you can contact us at 1-888-WELDALOY or our C10100 OFE Copper Forgings website to discuss your project. Our experienced staff can give you the information that you need to make the best possible decision about using our products.