Forging refers to the manufacturing process that involves the shaping of metals through processes like rolling, pressing, or hammering. The delivery of the compressive force is done with either a die or a hammer.
The other thing to note is that forging is either cold, warm, or hot, and the categorization of forging is based on the temperature that forging takes place.
While forging is typically done on the heavier metals like stainless steel, carbon steel, or alloy steel, softer metals like copper, brass, and aluminum can also be forged. During the forging process, parts with impressive mechanical capabilities/ properties are produced, with minimum production of waste.
Why is Forging Necessary?
- High strength and fatigue resistance
Basically, forging takes the original metal, and then it deforms the metal plastically to achieve the desired geometric shape. By doing this, the forged metal gains a higher level of fatigue resistance, and it also becomes stronger.
In the metal forging world, every forged metal turns into a superior quality metal with superior density, as well as directional strength.
- Economical Process
Forging copper (and other metals) is economically reasonable as it allows for the mass production of metal parts.
- Boost in durability
Forged copper or brass, like any other forged metal, will have an unparalleled level of durability after forging.
Essentially, copper is non-magnetic, corrosion-resistant, it has high ductility, it boasts a high electrical/ thermal conductivity, it’s highly ductile, and it boasts excellent plating characteristics. Forging would, therefore, reinforce these characteristics of copper, making it more durable and ideal for a host of industrial applications.
- An ideal choice for high-efficient motors
One of the most common applications for forged copper is in high-efficient motors. This application has seen an increased demand for forged metal.
Note that the top reasons for the use of copper in motors has to do with copper’s electrical conductivity that’s enhanced by forging. These properties of copper account for the use of the metal in advanced motors.
According to Queen City Forging, despite the high-stress forging process, the structural integrity of the metal is not affected by forging. Therefore, despite the common use of copper castings and the weldments, the traditional technique applied in the manufacture of copper, forging effects, and the resultant metallurgical applications cannot be replicated.
- Versatility
The other reason why forging of copper is common, even recommended, has to do with the popularity of the metal, and the fact that it’s been used for flanges, valves, compressors, and pumps, around caustic materials and chemicals that would cause tarnishing of other metals.
Why not casting?
While casting would be the other technique recommended in the metal manufacturing world, the truth is that forgings tend to be stronger than castings. The castings lack the strengthening benefits that are yielded by the hot or cold forgings and also forging surpasses the predictable strength properties of casting.
Forging also produces superior quality, resistant, and highly ductile pieces that boast uniform quality across and during the production runs.
Finally, unlike casting, forging will refine all the defects for the cast ingots or even the continuous cast bars. Casting lacks both grain flow and the directional strength achieved via forging.
