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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Our Upset Forging Process

Material Preparation

The process begins with selecting and preparing the metal billet. The material is heated to a specific temperature to improve flexibility and ease deformation.

Positioning the Billet

The heated billet is positioned in the forging machine. Proper alignment is important for achieving the desired shape and dimensions during the forging process.

Deformation Application

The forging machine applies controlled force to the billet through steps. This stepwise deformation gradually shapes the metal into the desired axisymmetric form.

Cooling and Inspection

The forged component is allowed to cool after deformation. It is then inspected for dimensional accuracy and defects, ensuring it meets quality standards.

Secondary Operations

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.

Final Quality Control

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 Alloys

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 Alloys

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 Alloys

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 Alloys

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 Alloys

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.

Magnesium Alloys

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.

ASTM A 105/A 105M

Ensures materials meet mechanical properties and performance standards for carbon steel used in upset forging.

ISO 9001:2015

Confirms Frigate's quality management system ensures consistent, high-quality products and customer satisfaction across production processes.

RoHS 2011/65/EU

Ensures materials used in upset forging are free from hazardous substances, promoting environmental sustainability and safety.

REACH Regulation (EC) No 1907/2006

Guarantees that chemicals used in upset forging processes are registered and evaluated for safety and environmental impact.

AS9100D

Acknowledges Frigate’s adherence to stringent aerospace industry standards for producing critical, high-performance forged components.

ISO/TS 16949:2009

Ensures that Frigate meets the highest standards for automotive industry suppliers, guaranteeing defect-free products and on-time delivery.

Tolerance for Upset Forging Services

Upset Length

±0.1 mm to ±0.3 mm

Controls the length of the upset portion for precise component sizing.

Upset Diameter

±0.2 mm to ±0.5 mm

Ensures consistent diameter in the upset area for fit and function.

Flow Line Orientation

±5° from axial direction

Ensures the grain flow aligns with the part’s stress direction for enhanced strength.

Flange Thickness

±0.2 mm

Controls the uniformity of flange thickness to ensure proper load distribution.

Forged Thread Tolerance

ISO 965-1 Class 6H

Ensures high-precision threading on upset forged components for threaded parts.

Critical Diameter

±0.1 mm to ±0.3 mm

Controls specific diameters critical for mating or assembly of components.

Hardness After Forging

350-450 HB

Ensures the forged part meets hardness requirements for specific applications.

Decarburization Depth

≤ 0.15 mm

Limits carbon loss during forging to maintain material strength and durability.

Barrel Distortion

≤ 0.25 mm

Minimizes distortion due to thermal expansion, ensuring part uniformity.

Die Wear Allowance

±0.1 mm per 1000 parts

Compensates for die wear to maintain consistent part dimensions over time.

Quality Testing Standards for Upset Forging Services

Forgeability

Compression Test

Assesses the material's ability to form under pressure without cracking.

Material Composition

Spectrometer Analysis

Ensures the alloy composition matches specifications for performance and strength.

Residual Stress

X-ray Diffraction or Strain Gauges

Measures internal stresses that may affect the part's performance or integrity.

Heat Treatment Response

Differential Thermal Analysis (DTA)

Analyzes the material's response to heat treatment processes to optimize properties.

Elongation at Break

Tensile Test (ASTM E8)

Measures how much the material stretches before breaking, indicating ductility.

Bonding Integrity

Shear Test or Peel Test

Evaluates the strength of the bond in areas where multiple materials are joined.

Formability Under Pressure

Hydraulic Press Test

Measures how the material behaves under extreme pressure, ensuring uniform deformation.

Microstructure Homogeneity

Scanning Electron Microscopy (SEM)

Assesses the uniformity of the microstructure to ensure consistent material properties.

Work Hardening

Hardness Gradient Testing

Measures the hardness distribution across the part to assess its work-hardened state.

Surface Integrity

Eddy Current Inspection

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

What You Get

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.

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What Our Customers Say about 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!

Thank you so much for your great support so far. Overall, the sheet metal work of the Plotbot Pro was done in an awesome way.Special Mention: The powder coat looks cooler!

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.

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.

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

What types of materials are best suited for upset forging?

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.

How does upset forging improve the mechanical properties of the final product?

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.

What is the significance of temperature control in upset forging?

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.

How does the tooling design affect the upset forging process?

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.

What role does upset forging play in reducing production time and costs?

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

23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ