Upset Forging Services
Frigate specializes in upset forging, producing high-strength components by deforming heated metal billets. This technique enhances material properties and ensures superior performance for intricate shapes in industrial applications.
Our Clients
Advantages of Upset Forging with Frigate
Grain Structure Optimization
Upset forging realigns the grain structure of the metal, enhancing strength and toughness, which contributes to the component's overall performance.
Controlled Deformation
The process allows for precise control over the deformation of heated billets, resulting in accurate dimensions and reduced machining requirements post-production.
Material Utilization
Upset forging effectively uses the available material, significantly minimizing scrap rates and improving material yield compared to other forging methods.
Thermal Management
The process often incorporates controlled heating techniques, ensuring uniform temperature distribution and enhancing the final product's mechanical properties.
Innovative Forging Solutions for Complex Components
As an extension of hot forging, upset forging efficiently produces elongated parts in high volumes. This technique uses stepwise deformation of the metal head to create axisymmetric components with complex shapes. It ensures consistent dimensional accuracy and mechanical integrity for demanding applications. Frigate employs advanced upset forging technology and specialized tooling. This optimizes production efficiency and minimizes material waste. Frigate addresses the challenges of intricate designs by focusing on precision and quality control. Components meet strict industry standards.
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- Instant Quotation
- On-Time Delivery
- Affordable Cost
Our Upset Forging Process
The process begins with selecting and preparing the metal billet. The material is heated to a specific temperature to improve flexibility and ease deformation.
The heated billet is positioned in the forging machine. Proper alignment is important for achieving the desired shape and dimensions during the forging process.
The forging machine applies controlled force to the billet through steps. This stepwise deformation gradually shapes the metal into the desired axisymmetric form.
The forged component is allowed to cool after deformation. It is then inspected for dimensional accuracy and defects, ensuring it meets quality standards.
Depending on the application, secondary operations such as machining, heat treatment, or surface finishing may be performed to achieve the required tolerances and surface qualities.
The finished components undergo a final quality control check. This ensures that they meet all specifications and performance criteria before being delivered for use.
Upset Forging Materials
Upset forging effectively increases material density and strength in critical areas. This process resolves challenges related to part integrity and performance in demanding applications.
Steel is the most commonly used material in upset forging. Various alloy compositions, such as carbon steel, alloy steel, and stainless steel, offer different mechanical properties. Carbon steel provides strength and flexibility, while alloy steels enhance toughness and wear resistance.
Aluminum is lightweight yet strong, making it a popular choice for upset forging. Aluminum alloys, such as 6061 & 7075, exhibit high strength-to-weight ratios and good corrosion resistance. They are often used in aerospace and automotive applications where reducing weight is critical.
Copper and its alloys, such as brass and bronze, are known for their excellent thermal and electrical conductivity. They also possess good corrosion resistance and machinability. Copper alloys are frequently used in electrical components, plumbing fittings, and marine applications.
Titanium is recognized for its high strength, low density, and exceptional corrosion resistance. Titanium alloys, such as Ti-6Al-4V, are often used in aerospace, medical, and chemical processing applications. Upset forging of titanium allows for creating complex shapes while maintaining strength and durability.
Nickel-based alloys, such as Inconel and Monel, are used in high-temperature environments. These alloys provide excellent mechanical properties and resistance to oxidation and corrosion. Upset forging of nickel alloys is common in gas turbines and chemical processing equipment applications.
It is one of the lightest structural metals available. Magnesium alloys, such as AZ31 and AZ61, provide good strength and excellent machinability. They are often used in automotive and aerospace applications where weight reduction is essential.
Precision Custom Upset Forging Solutions
Custom upset forging delivers precision-engineered components through controlled deformation techniques. This creates high-strength, axisymmetric parts with complex geometries. The process optimizes material flow, enhancing mechanical properties and ensuring tight dimensional tolerances. Advanced tooling and technology minimize waste, increasing production efficiency and lowering costs. Tailored designs meet specific application requirements, ensuring components meet stringent performance standards. Custom upset forging is a valuable solution for improving operational effectiveness in demanding environments.
Compliance for Upset Forging Services
Frigate ensures precise materials and process control. Each forging undergoes testing for mechanical properties and dimensional accuracy. Materials are carefully selected for strength and performance. Heat treatment is precisely controlled for optimal properties and fatigue resistance. All processes are traceable and meet industry regulations, ensuring top product quality and integrity.
Ensures materials meet mechanical properties and performance standards for carbon steel used in upset forging.
Confirms Frigate's quality management system ensures consistent, high-quality products and customer satisfaction across production processes.
Ensures materials used in upset forging are free from hazardous substances, promoting environmental sustainability and safety.
Guarantees that chemicals used in upset forging processes are registered and evaluated for safety and environmental impact.
Acknowledges Frigate’s adherence to stringent aerospace industry standards for producing critical, high-performance forged components.
Ensures that Frigate meets the highest standards for automotive industry suppliers, guaranteeing defect-free products and on-time delivery.
Tolerance for Upset Forging Services
Controls the length of the upset portion for precise component sizing.
Ensures consistent diameter in the upset area for fit and function.
Ensures the grain flow aligns with the part’s stress direction for enhanced strength.
Controls the uniformity of flange thickness to ensure proper load distribution.
Ensures high-precision threading on upset forged components for threaded parts.
Controls specific diameters critical for mating or assembly of components.
Ensures the forged part meets hardness requirements for specific applications.
Limits carbon loss during forging to maintain material strength and durability.
Minimizes distortion due to thermal expansion, ensuring part uniformity.
Compensates for die wear to maintain consistent part dimensions over time.
Quality Testing Standards for Upset Forging Services
Assesses the material's ability to form under pressure without cracking.
Ensures the alloy composition matches specifications for performance and strength.
Measures internal stresses that may affect the part's performance or integrity.
Analyzes the material's response to heat treatment processes to optimize properties.
Measures how much the material stretches before breaking, indicating ductility.
Evaluates the strength of the bond in areas where multiple materials are joined.
Measures how the material behaves under extreme pressure, ensuring uniform deformation.
Assesses the uniformity of the microstructure to ensure consistent material properties.
Measures the hardness distribution across the part to assess its work-hardened state.
Detects surface cracks and material inconsistencies that may affect performance.
Transforming Aerospace Component Manufacturing
Aerospace manufacturing faces challenges like strict weight limits and high-strength requirements. Upset forging effectively addresses these issues by creating lightweight, axisymmetric parts with excellent mechanical properties. This process optimizes material flow for tight tolerances and consistent quality. Forming complex shapes reduces the need for additional machining, lowering production time and costs. By delivering reliable components that meet rigorous standards, upset forging enhances performance and safety in aerospace applications, improving overall efficiency.
Industries We Serve
- Solid Progress
What You Gain with Us
We make your profitability and operations easier with practical approach.
↓ 7-8%
OPS COST
↓ 2-3%
COGM
3X
Aggregation
↑ 25%
Machinery Utilisation
↓ 50%
Expedition
↑ 30%
Frigater Revenue
- Solid Progress
Our Manufacturing metrics
Frigate brings stability, control, and predictable performance to your sourcing operations through a structured multi-vendor system.
2.8X
Sourcing Cycle Speed
Frigate’s pre-qualified network shortens decision time between RFQ and PO placement.
94%
On-Time Delivery Rate
Structured planning windows and logistics-linked schedules improve project-level delivery reliability.
4X
Multi-Part Consolidation
We enable part family batching across suppliers to reduce fragmentation.
22%
Quality Rejection Rate
Multi-level quality checks and fixed inspection plans lower non-conformities.
30%
Procurement Costs
Optimized supplier negotiations and bulk order strategies reduce your overall sourcing expenses.
20%
Manual Processing Time
Automation of sourcing and supplier management significantly reduces time spent on manual tasks.
Complex Shapes, Simplified Solutions
Complex shape fabrication is essential for aerospace components. Intricate designs must meet aerodynamic and functional requirements. This is crucial for optimal performance. Upset forging technology enables precise material deformation. It creates advanced geometries while preserving structural integrity. Frigate employs specialized tooling and innovative techniques. This approach addresses challenges in complex shape fabrication. It also minimizes waste and production time, enhancing reliability and efficiency in aerospace applications.
Get Clarity with our Manufacturing Insights
- Satisfied Customers
Excellence You Can Trust
Trusted by Fortune 500 companies for high-precision CNC machining, tight tolerances, and superior quality.
“Quick turnaround and solid quality.”
“The instant quote tool saved us time, and the parts were spot-on. Highly recommend Frigate!”
“I would strongly recommend Frigate to anyone who wants to do Rapid Prototyping, and 3D Printing and take their ideas to manufacturing. One firm doing all kinds of Product Development!”
“Great service, fair price, and the parts worked perfectly in our assembly.”
“Top-notch machining and fast shipping. Very satisfied with the results.”
“The next disruption is happening in Prototyping & Manufacturing on-demand and Frigate is leading the way!I personally believe the Frigate's way of IIOT enabled cloud platform with Al.”
“Frigate delivered high-quality parts at a competitive price. The instant quote tool is a huge plus for us!”
“We appreciate the precision and quality of the machined components in the recent delivery—they meet our specifications perfectly and demonstrate Frigate’s capability for excellent workmanship.”
“Flawless execution from quote to delivery.”
“I am absolutely happy to work with supplier like Frigate who were quite proactive & result oriented . Frigate has high willingness team who has strong know how & their passion towards the products & process were absolutely thrilling.”
“The precision on these parts is impressive, and they arrived ahead of schedule. Frigate’s process really stands out!”
“Parts were exactly as spec’d, and the instant quote made budgeting a breeze.”
“Good value for the money.”
“The finish was perfect, and the team was easy to work with.”
“Working with Frigate has been great. Their proactive, results-driven approach and expertise shine through in every project. It's been a pleasure collaborating with them.”
Having Doubts? Our FAQ
Check all our Frequently Asked Question
Upset forging works well with ductile materials like carbon steel, alloy steel, and certain aluminum alloys. These materials maintain strength during deformation, allowing for high-quality components.
Upset forging aligns the material's grain structure, enhancing strength and toughness. This process also reduces porosity and defects, resulting in components with superior fatigue resistance.
Temperature control is critical in upset forging. Maintaining optimal temperatures ensures proper material flow and minimizes the risk of cracking. It also allows for better dimensional accuracy in the final shape.
Tooling design directly influences the accuracy and efficiency of upset forging. Well-designed dies to ensure uniform deformation and proper material flow, leading to reduced waste and improved surface finish.
Upset forging allows for rapidly producing complex shapes with fewer machining steps. This efficiency reduces cycle times and material waste, ultimately lowering production costs.
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LOCATIONS
Global Sales Office
818, Preakness lane, Coppell, Texas, USA – 75019
Registered Office
10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.
Operations Office
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
Other Locations
- Bhilai
- Chennai
- Texas, USA
