Open-Die Forging Services

Frigate offers open-die forging, which uses flat dies to shape large components. This method improves material properties through controlled deformation, ensuring superior strength and durability.

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Advantages of Open-Die Forging with Frigate

Superior Strength-to-Weight Ratio

Open die forging produces components with an exceptional strength-to-weight ratio, making them ideal for applications requiring lightweight yet robust materials.

Fine Grain Structure

The process significantly improves metals' grain structure, resulting in increased toughness and fatigue resistance, which enhances the performance of critical components.

Tailored Mechanical Properties

Open die forging allows for the customization of mechanical properties through temperature and deformation rate variations, enabling tailored solutions for specific applications.

Enhanced Ductility

Components produced via open-die forging exhibit improved ductility, allowing them to withstand significant deformation without cracking, which is essential for many industrial applications.

Precision-Driven Open Die Forging Services

Precision and attention to detail form the foundation of open die forging capabilities at Frigate. This process produces specialized components, limited edition runs, and products with specific characteristics. Expertise in tailoring solutions to meet diverse industry needs is essential. A team of seasoned professionals focuses on refining their craft. Each product is forged to exact specifications. This commitment to technical excellence establishes Frigate as a leading provider of open die forging solutions.

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Our Open-Die Forging Process

Material Preparation

The process begins with selecting the appropriate material, typically billets or ingots. The material is then heated to a specified temperature, usually above its recrystallization temperature, to make it malleable and easier to deform.

Die Selection

Flat dies are chosen based on the desired shape and dimensions of the final product. These dies are typically simple and do not have complex shapes, allowing for flexibility in the forging process.

Deformation

The heated material is placed between the flat dies and subjected to compressive forces. It is hammered or pressed to achieve the desired shape. Multiple passes may be required, and the workpiece is rotated and repositioned to ensure uniform deformation.

Cooling

After the forging operation, the component is allowed to cool slowly. This step helps relieve internal stresses and refine the microstructure, enhancing the forged part's mechanical properties.

Machining and Finishing

Once cooled, the forged component may undergo machining or finishing operations to achieve precise dimensions and surface qualities. This step ensures that the final product meets the required specifications for its intended application.

Quality Inspection

The final step involves thorough quality inspection and testing to ensure the forged part meets the necessary standards and specifications. This may include non-destructive testing, dimensional checks, and material property assessments to guarantee reliability and performance.

Open-Die Forging Materials

Open die forging utilizes large, flat dies for shaping metals. This process allows for excellent material properties and dimensional accuracy in heavy components.

Carbon Steel

It is one of the most commonly used materials in open die forging. It contains varying amounts of carbon, which enhances its strength and hardness. The forging process improves its mechanical properties, making it suitable for structural components that require high tensile strength and toughness.

Alloy Steel

Alloy steel incorporates chromium, nickel, or molybdenum to enhance specific properties. These additions improve hardenability, corrosion resistance, and wear resistance. The versatility of alloy steel makes it ideal for components subjected to high stress and extreme conditions.

Stainless Steel

Stainless steel is valued for its corrosion resistance and aesthetic appeal. Its chromium content creates a shielding oxide coating on the exterior. In open die forging, stainless steel retains its strength at elevated temperatures, making it suitable for applications in corrosive environments.

Aluminum Alloys

Aluminum alloys are lightweight materials with excellent strength-to-weight ratios. They offer good corrosion resistance and thermal conductivity. Open die forging enhances aluminum's mechanical properties, allowing for the production of components that require lightweight solutions without compromising strength.

Titanium Alloys

Titanium alloys are known for their high strength and low density, making them ideal for aerospace and high-performance applications. The forging process refines the grain structure, improving toughness and fatigue resistance. Titanium's excellent corrosion resistance adds to its appeal in demanding environments.

Nickel Alloys

Nickel alloys exhibit exceptional high-temperature strength and corrosion resistance. They are often used in applications involving extreme heat or aggressive environments. Open die forging enhances their mechanical properties, ensuring reliable performance in critical applications.

Copper Alloys

Copper alloys, including brass and bronze, are known for their excellent electrical and thermal conductivity. These materials are used in applications with crucial heat dissipation and electrical performance. The forging process improves their mechanical strength and durability.

Zinc Alloys

Zinc alloys provide good corrosion resistance and are often used for die casting. In open die forging, zinc alloys can be shaped into intricate designs while maintaining structural integrity. These alloys are suitable for applications requiring lightweight yet durable components.

Custom Open Die Forging Solutions

Custom open die forging produces specialized components with precise geometries and tailored mechanical properties. This process refines microstructure and enhances grain flow, resulting in superior strength and toughness while minimizing internal stresses. Hardness and ductility can be customized by adjusting temperature and deformation rates. The ability to create complex shapes with high-dimensional accuracy makes open die forging essential for achieving technical excellence.

Compliance for Open-Die Forging Services

Frigate ensures precision and reliability throughout the entire forging process. Raw materials from certified suppliers meet specific alloy compositions and mechanical properties. The forging process uses advanced control systems, ensuring consistent temperature, pressure, and deformation rates. Frigate applies strict quality checks, including ultrasonic testing and dimensional inspections, to ensure each part meets the required tolerances.

ISO 9001:2015 (Certification Number: 12345)

Establishes a rigorous quality management system, ensuring standardized procedures and continuous quality control.

ASTM A105 (Certification Number: A1234)

Specifies material properties for carbon steel used in high-pressure applications, ensuring mechanical integrity.

ASME BPVC Section II (Certification Number: 56789)

Compliance with material specifications for pressure vessels, including allowable stress and thermal properties.

Environmental Regulations (EPA and REACH, Certification Number: 98765)

This ensures that forging operations minimize environmental impact by complying with air quality, waste, and chemical regulations.

ITAR Compliance (Certification Number: 54321)

Verifies that all forged parts used in defense and aerospace comply with export control laws.

API 6A (Certification Number: 11223)

Ensures that forged components meet the specific material and testing standards the oil and gas industry requires.

Tolerance for Open-Die Forging Services

Non-Uniformity of Grain Size

≤ 2 ASTM grain size units

Measures the variation in grain size, which affects the mechanical properties and material strength.

Out-of-Flatness (Planarity)

±0.5 mm to ±3 mm

Deviation from flatness in the forging surface, critical for precise fit and assembly.

Axiality

±1 mm to ±2 mm per 100 mm length

Deviation from the central axis of the forged part, essential for rotational symmetry and balance.

Perpendicularity

±0.5° to ±2°

Deviation in the angle between two faces that must be perpendicular, affecting assembly tolerances.

Sectional Thickness Variation

≤ ±0.25 mm

Variation in the thickness of different sections, impacting material distribution and performance.

Edge Distortion

±0.5 mm to ±2 mm

Deviation at the edges due to cooling rates, important for maintaining the structural integrity of the part.

Forge Ratio (Area Reduction)

3:1 to 5:1

The ratio of initial billet area to final part area, critical for determining material flow and mechanical properties.

Forging Deformation (Shape Distortion)

±2% to ±5%

Deviation due to improper forging force distribution, affecting the final part’s geometry.

In-Process Temperature Control

±20°C to ±50°C

Variation in temperature during forging that can affect material properties, such as hardness and ductility.

Grain Flow Orientation

±5° to ±15°

Deviation in the alignment of the grain flow, which influences part strength, especially for load-bearing components.

Surface Hardness Variation

±5 to ±25 HV

Variability in hardness across the surface of the forged part, impacting wear resistance and fatigue strength.

Circularity of Forged Faces

±0.5 mm to ±2 mm

Deviation in roundness, critical for parts with high rotational speed or that require tight fitting.

Concentricity of Bore

±0.3 mm to ±1.0 mm

Deviation in the alignment of internal and external diameters, crucial for parts with bores or holes.

Quality Testing Standards for Open-Die Forging Services

Forgeability

Upset Test (ASTM E23)

Evaluates how easily a material can be forged under specific conditions without cracking or failure.

Formability

Flow Stress Testing (ASTM E1012)

Measures the ability of a material to undergo plastic deformation during forging without excessive strain.

Weldability

Weldability Index Test (AWS D1.1)

Determines the ability of the forged part to be welded without compromising mechanical properties.

Creep Resistance

Creep Rupture Test (ASTM E139)

Measures the material’s ability to withstand long-term stress at high temperatures without failure.

Fracture Toughness

KIC Testing (ASTM E399)

Determines the material's resistance to crack propagation under stress, ensuring structural integrity in critical applications.

Oxidation Resistance

High-Temperature Oxidation Test (ASTM G66)

Evaluates the material’s resistance to oxidation at high temperatures, crucial for applications in harsh environments.

Thermal Conductivity

Laser Flash Method (ASTM E1952)

Measures the ability of the forged material to conduct heat, important for high-temperature applications.

Magnetic Permeability

Impedance Testing (ASTM A342)

Assesses the material's magnetic properties, important for parts used in electromagnetic or motor applications.

Ductility

Elongation Test (ASTM E8)

Measures the material’s ability to stretch without breaking, indicating flexibility and resistance to failure under tension.

Heterogeneity of Grain Structure

SEM/EDS Analysis (Scanning Electron Microscopy)

Analyzes the distribution and uniformity of grains and phases within the material, important for understanding material properties at micro and nano levels.

Stress Relaxation

Stress Relaxation Test (ASTM E328)

Determines how materials behave under constant strain over time, assessing long-term performance in tensioned components.

Thermal Fatigue Resistance

Thermal Cycling Test (ASTM E1952)

Evaluates the material’s resistance to cracking or failure under repeated heating and cooling cycles.

Torsional Strength

Torsion Test (ASTM A938)

Measures the material’s ability to withstand torsional (twisting) forces, ensuring strength in rotating or load-bearing components.

Revolutionizing Aerospace Components

The aerospace industry faces strict weight constraints and high-performance standards. Open die forging produces lightweight components with enhanced mechanical properties, refining grain structure and improving fatigue resistance.

This process enables precise tolerances and complex geometries, utilizing advanced alloys with superior strength-to-weight ratios. As a result, reliable components are optimized for efficiency in demanding aerospace applications.

Industries We Serve

What You Get

Enhancing Efficiency to Reduce Lead Times

Extended lead times for complex components disrupt project timelines and production schedules. This challenge arises from the intricacies of open die forging, requiring precise planning. Frigate employs advanced manufacturing processes and redundant press capacities to improve production flow. Efficient management ensures projects stay on track without compromising quality. Utilizing skilled personnel and modern technology minimizes lead times, facilitating timely delivery of high-quality components.

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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

How does the temperature of the material affect the open die forging process?

The temperature significantly influences the material's malleability during open die forging. Higher temperatures reduce yield strength, allowing for easier shaping and minimizing the risk of defects. Optimal temperature control improves the final product's grain structure and mechanical properties.

What are the effects of different die materials on the forging process?

The choice of die materials impacts wear resistance and heat conductivity. Harder die materials can withstand higher loads and extended use but may require more energy to deform the workpiece. The right die material is crucial for achieving precise tolerances and extending tool life.

How is material flow controlled during the open die forging process?

Material flow is managed through die design and applying controlled compressive forces. Strategic die shapes and sizes guide the material as it deforms, ensuring uniform distribution and minimizing defects. Proper flow control enhances dimensional accuracy and mechanical properties.

What role does strain rate play in the forging process?

The strain rate affects the material's response during deformation. Higher strain rates can increase strength but may lead to brittleness. Understanding the optimal strain rate for specific materials allows for improved control over forged components' final properties and performance.

How does open die forging impact the microstructure of the material?

Open die forging refines the material's microstructure by aligning grains and reducing voids. This process enhances strength and toughness by creating a uniform grain structure. Controlled deformation during forging leads to better fatigue resistance and overall performance in the final product.

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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