A common way to manufacture a metal component is by using the method of drop forging. But what sets this method apart and makes drop forgings so remarkably strong and tough? There are actually two key reasons why drop forging creates such well-built products and is a go-to process for many manufacturers: predictable grain structure and uniformity.
Predictable Grain Structure
The age-old process of drop forging involves heating a billet and placing it into a die, where it then is put under extreme pressure by a “hammer” and forced into the die’s shape. During this process, the grain flow of the metal is actually altered, conforming to the shape of the part. A high-quality drop forging process makes the metal component stronger, tougher and much more reliable. The importance of grain structure cannot be underestimated. The process of bar stock and plate machining, for example, creates unidirectional grain flow. This means that any changes to the contour will ultimately cut flow lines, exposing the grain ends and making the metal more vulnerable to fatigue and corrosion.
The grain structure and flow created during the drop forging process is directional and has been placed in a way as to increase the strength and toughness of the part, thus creating overall directional strength. Since no grain ends are exposed, a drop forged metal component is less susceptible to wear and tear.
Uniformity
Drop forgings ensure there are no internal gas pockets or voids that can cause unexpected accidents when under stress or impact. This virtually eliminates weak metal parts and creates superior grain-size uniformity. Directional grain orientation, removal of porosity and grain-size uniformity are why drop forging is the method used when reliability and safety are critical. Forged metal parts are most often used in items such as airplanes, automobiles, ships and engines, all instances where human safety is on the line.
Grain-size uniformity is key to designers in that it means the material will respond predictably to its environment without internal defects. Drop forgings mean consistent reactions to heat treatment, overall uniform machinability and reduced inspection requirements. All of these factors contribute to faster production, lower costs and a strong, tough, superior product.
Let Canton Drop Forging Help You Today
In need of our help? At Canton Drop Forge, we offer a wide range of services. And with more than 100 years of experience, we have the knowledge and expertise to get the job done right, every time. Need a quote or more information? Reach out to our drop forging experts today.