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Forging is a manufacturing process that many industries rely on. In fact, hundreds of forged components can be found in aircraft, vehicles, farming equipment, trains, mining machinery, and more. When compared to other processes, like casting and fabrication welding, forgings are stronger and more reliable. Additionally, because the metal forging process can produce complex geometries efficiently, it can be a more cost-effective manufacturing process.

One common misconception is that forging is one universal method; in reality, there are several methods that a forging manufacturer may use. In general, forging can be classified in two ways: by the tooling and by temperature.

In this article, we’ll cover each forging method, as well as highlight the main types of equipment used in forging.

Let’s start with the first classification: forging by tooling

In the global foundry industry, one-fifth of the foundries are for automobiles. It is estimated that an average car is assembled from more than 20,000 parts, and about 20 per cent of the parts are cast in various processes.

Galvanizing refers to the surface treatment technology of plating a layer of zinc on the surface of metals, alloys or other materials to play the role of aesthetics and rust prevention. The main methods used are hot dip galvanizing and electric galvanizing

Anodising is the electrochemical oxidation of metals or alloys. The principle is to use the metal or alloy parts as anode, using electrolysis method to make its surface form oxide film.

The global metal casting market size reached US$ 165.0 Billion in 2023. Looking forward, the market is expected to reach US$ 314.9 Billion by 2032, exhibiting a growth rate (CAGR) of 7.3% during 2024-2032. The market is experiencing robust growth driven by the increasing demand from the automotive and aerospace industries, rapid technological advancements, sudden shift towards using recycled metals, expanding construction and infrastructure projects, and the rising investments in the defense and military sector.

Low pressure die casting is used fill the molten metal into the mold. In low pressure die casting, the die is filled with metal from a pressurised furnace, with pressures typically around 0.7 bar. The holding furnace is positioned in the lower part of the vertical die casting machine, with the molten metal injected upwards directly into the bottom of the mould.

Shell casting is especially suitable for the production of large batches, high dimensional accuracy requirements, thin walls and complex shapes of various alloy castings.

Gravity casting refers to the process of injecting metal liquid into the mold under the action of Earth gravity, also known as gravity casting.

Metal stamping is a manufacturing process used to convert flat metal sheets into specific shapes. It’s a complex process that can include a number of metals forming techniques—blanking, punching, bending and piercing etc. It is a fast and cost effective solution for large-quantity manufacturing need.

All metal casting processes involve the creation of a mold into which molten metal is poured. The outstanding precision and excellent as-cast surface finishes achieved with investment casting are the result of a very precise series of steps as follows: