Drop forging is a process where a metal bar will be heated up and then placed in a die and hammered until the metal fills the die space. The metal will then be lifted and dropped onto the hot piece of metal until the desired shape is achieved.
The metal is preheated to soften the structure, it can then be moulded by the hammer in a controlled manner to achieve the desired shape. In drop forging the metal gains its strength by cooling down and solidifying.
The most common two types of drop forging are open die forging and closed die forging. Closed die forging will cover the item being forged, whereas open die forging does not.
Drop forging reduces the possibility of a defect in the metal, things like alloy segregation or porosity can be found in some castings, this can lead to reduced scrap.
Drop forging cycle times should be quick, usually, a basic forging can be completed within 30 seconds, although if a more complex shape or design is required it could take longer. Of course, this can all depend on the level of skill and experience the forger has.
Many types of metal can be forged, things such as carbon, stainless steel and alloy, these are all ferrous metals, a few non-ferrous metals can also be forged, things like aluminium, copper brass and titanium are also suitable for drop forging.
If you work in the forging industry, you will know it can be a dangerous place to work, so the health and safety rules must have adhered too.
Many industries rely on drop forging to produce the products they need, such as construction, rail, and sea defence. The Drop forging process is known for its strength and durability, so is widely used as a necessity in these fields.