Forgings stand out for their optimized grain flow, which enhances fibre alignment and significantly improves structural integrity, making them ideal for critical applications such as bolts, pinions, gear wheels, and pressurised components. In closed-die forging, materials like steel and superalloys are reshaped between two die halves or, in some cases, additional die segments, further strengthening the component by aligning its internal grain structure. Forging materials that are challenging to work with, such as titanium alloys or duplex stainless steel, requires expert handling due to their high strength and low forgeability. Unlike casting, forging refines the internal structure, minimising defects like porosity and significantly improving overall mechanical properties.
Forging vs. Casting
In casting, raw materials are poured into moulds, resulting in a structure lacking specific grain alignment. This can lead to various defects, such as porosity, inclusions, and shrinkage, ultimately compromising the structural integrity of the finished product. In contrast, forging inherently avoids these issues by refining the internal structure, leading to superior strength and fatigue resistance.
Forged parts consistently exhibit greater reliability compared to their cast counterparts. Although casting can create intricate shapes and hollow structures, the mechanical performance of cast components is often compromised by inherent defects and a suboptimal microstructure, which can lead to issues such as lower mechanical strength and ductility. Therefore, for applications demanding high strength and structural integrity-such as bolts, gear wheels, and pressurised components -forging remains the superior choice.
The above image features the author, Thomas Henneke, managing partner of KB Schmiedetechnik GmbH, presenting forged sling and lifting gear at an exhibition booth:
"For 20 years, we have been assisting our clients in optimising forged components through material flow simulation and advising on the transition from assemblies such as welded structures or cast parts to forged components with optimised grain flow."
Examples: forged holders, hoists, hooks, eyelets, chain links, lifting gear, special nuts, bolts and screws, forged gear blanks and pinions, pipe connections, and pressure-bearing components. Additionally, forged parts for nuclear, hydrogen, and cryogenic valves, parts for boiler systems and power plants in general, as well as seawater-compatible components designed for corrosive applications in naval vessels, shipyard supplies, and military and defence applications.
The interested reader can find an image gallery of KB and additional information about the author here: https://waisch.ch/firma/la-forge-kb-schmiedetechnik-gmbh-hagen-nrw/posts/cv-and-publications-by-thomas-henneke
KB Schmiedetechnik GmbH is a highly certified German drop forge, located in Hagen (Westphalia) - between the historic "blade & metal" region Solingen and the "soccer city" Dortmund - specializing in small series production of safety-relevant closed die forgings from 200g to 130Kg unit weight of all steel grades including duplex stainless steels, nickel based and titanium alloys according to following standards, norms and certifications - these can be downloaded from the company´s website under "quality":
ISO 9001+14001 and
Shipbuilding:
Forgings - Made in Germany of European quality steel!
Forgings made in Germany by KB Schmiedetechnik GmbH