Custom Steel Forgings Company
Manufacturing Process of Steel Forging Parts
Steel Open-die Forging
Steel open-die forging works by heating steel first. A hammer or press then hits the metal directly. This force slowly shapes the steel into the final size and shape needed.
Highly Flexible: No fixed mold is needed. We can make steel forgings of many different shapes.
Large and Strong: It can make very large, high-strength steel parts.
Low Cost for Small Jobs: The cost is low. It is great for making just one part or small batches of parts.
Steel Closed Die Forging
Steel closed-die forging heats the steel to a set temperature. Then, a special closed die presses the metal into shape. This method makes steel forgings that are very precise. They have great strength and a good surface finish.
Mass Production: This process is perfect for making parts in large numbers.
High Accuracy: The steel forgings come out with very exact size and dimensions.
Excellent Strength: The steel forgings have superb mechanical properties.
Steel Ring Forging
This forging method makes steel parts shaped like rings. We heat the steel blank first. We put the hot steel into a mold or forging equipment. We then use pressure. This forces the metal to flow and form the final steel ring forging.
Used to make parts with complex shapes easily.
Best for medium and large production runs.
The final forgings have high strength and toughness.
Steel Cold Forging
Steel cold forging shapes a steel blank at room temperature. We use pressure to change the steel's shape without heating it. This method creates parts with high precision and better mechanical strength.
Precise Finish: Parts have very close size limits (tight tolerances) and a good surface finish.
Stronger Steel: It boosts the steel's strength and hardness, making the part last longer.
Saves Material: It cuts down on wasted material and the need for extra machining.
High Performance: The steel forgings come out with higher strength and toughness.
Heat Treatment
Heat treatment changes the inside of steel parts. It uses steps like heating, holding heat, and cooling. This process makes the metal better. It improves how steel parts work, helps them last longer, and makes them easier to shape.
It makes steel parts harder and stronger.
It improves the toughness of the steel.
It boosts wear resistance and corrosion resistance (fighting rust).
Machining
Machining is a final step for steel forgings. It uses fine tools to improve the parts. This work boosts the accuracy, makes the surface much cleaner, and improves what the forging can do.
It makes the final look better.
It improves the part's structure and function.
It lets us make thin walls and complex shapes.
Different Materials of Steel Forgings
Carbon Steel Forging
Forging carbon steel heats the metal until it's soft. Then, a hammer or press applies pressure to shape it. Forging greatly improves the grain structure. It removes inside flaws, boosting the steel's strength. This makes it ideal for critical parts that need high reliability and strength.
Superior Strength: Forging refines the grain and makes the metal denser. This results in better tensile strength, fatigue life, and impact toughness than cast or machined parts.
Flawless Inside: Forging removes internal flaws like holes and shrinkage spots found in castings. This ensures high reliability and safety.
Continuous Grain Flow: The grain structure follows the part's shape. This gives the best strength right where it's needed, improving resistance to breaking from stress or impact.
Cost-Effective for Big Jobs: For making many complex parts, forging is cheaper than cutting them from solid stock. Plus, it gives better strength.
Easy to Machine: Forged carbon steel machines well when it's been normalized or annealed. This allows for precise final shaping.
Forged Carbon Steel Parts from Simis Steel Forging Factory:
Car crankshafts and connecting rods;
gears and transmission shafts;
hand tools (wrenches, hammers);
construction machine parts;
railway axles and wheels;
industrial shafts and couplings.
Carbon Steel Forging Categories Simis Uses:
Low Carbon Steel Forgings (Carbon ≤ 0.25%):
Uses: General structural parts, car body parts, construction hardware, and case-hardened components.
Grades: SAE 1008, 1010, 1015; ASTM A668 Class A.
Medium Carbon Steel Forgings (Carbon 0.25% - 0.60%):
Uses: Car crankshafts, connecting rods, gears, axles, and strong structural parts.
Grades: SAE 1045, 1050; ASTM A668 Class D (C45).
High Carbon Steel Forgings (Carbon ≥ 0.60%):
Uses: Cutting tools, springs, strong wire, wear parts, and railway wheels.
Grades: SAE 1060, 1070, 1080; ASTM A668 Class G.
Free-Cutting Carbon Steel Forgings:
Uses: High-volume parts that need a lot of machining, like fasteners, fittings, and car parts.
Grades: SAE 1117, 1144; ASTM A668 Class C.
Stainless Steel Forging
Forging stainless steel shapes the hot alloy under high pressure. Stainless steel has chromium and nickel to stop rust. Forging makes the metal's inside structure much better. The final parts are very strong and resist rust, heat, and cold well. Forged stainless steel is the best choice for parts in bad, rusty environments.
Very Strong: It is stronger than casting or machining. It handles impact and repeated stress better.
Rust Resistant: The process removes surface and internal flaws. This helps the part fight corrosion.
Reliable: It has no holes or cracks inside. This makes it safe and durable.
Handles Heat: It keeps its strength and resists rust even at high temperatures.
Smooth Surface: The finished part has a good finish. This means less extra work is needed.
Forged Stainless Steel Components by Simis Steel Forging Factory:
high-pressure flanges and valves for oil and gas;
important marine parts;
surgical tools and medical implants;
food processing parts;
chemical tank components;
turbine blades.
Forged Stainless Steel Categories used by Simis Steel Forging Factory:
Austenitic Stainless Steel
Use: Good for chemical, food, and medical parts.
Grades: ASTM A182 F304, F316.
Martensitic Stainless Steel
Use: Good for strong tools and parts like surgical instruments.
Grades: ASTM A182 F410, F420.
Duplex Stainless Steel
Use: Good for tough places like offshore oil rigs and chemical plants.
Grades: ASTM A182 F51, F53.
Alloy Steel Forging
Forging alloy steel adds specific elements like nickel and chromium to carbon steel before shaping it. The metal is heated and then pressed into form. This process boosts the steel's strength, hardening ability, and performance in harsh conditions. Forged alloy steel offers a better strength-to-weight ratio than carbon steel. It is essential for critical jobs where carbon steel is not strong enough.
Customizable High Strength: We can add alloys to reach very high strength and hardness. We fine-tune this strength using special heat treatments.
Hardens Deeply: Elements like chromium help the steel harden evenly, even in very large parts. This is key for heavy, high-stress components.
Fights Wear and Fatigue: The improved structure fights rubbing wear and metal fatigue well. This is due to the refined grain and added elements.
Works in Extremes: Some grades stay strong in very high heat (red hardness) or keep their toughness in extreme cold. This meets the needs of aerospace and energy fields.
Flawless Inside: Forging removes internal flaws (like holes) to ensure maximum metal density and safety in all parts.
Forged Alloy Steel Parts from Simis Steel Forging Factory:
Turbine and rotor shafts;
high-performance gears and pinions;
heavy-duty axles;
aircraft landing gear parts;
high-pressure valve bodies for oil and gas;
specialized tools and dies.
Alloy Steel Forging Categories Simis Uses:
Chromium-Molybdenum (Cr-Mo) Steels:
Uses: Strong shafts, gears, tool joints, and parts needing good toughness in moderate heat.
Grades: AISI 4130, 4140, 4150.
Nickel-Chromium-Molybdenum (Ni-Cr-Mo) Steels:
Uses: Critical parts needing the highest strength, toughness, and fatigue life (e.g., aircraft gear and heavy crankshafts).
Grades: AISI 4340, 8620, 9310.
Bearing Steels (High Carbon Chromium):
Uses: Parts needing extreme hardness and long rolling fatigue life (e.g., bearings and races).
Grades: AISI 52100.
Boron-Alloyed Steel
Use: Good for fasteners and automotive parts that need good hardenability.
Grades: SAE 15B21, 15B30.
Special Purpose Forged Steel
Special purpose forged steel is designed for jobs with extreme demands. This includes high heat, high pressure, or special wear. These steels use complex alloys (like high nickel, cobalt, or tungsten) to achieve traits that standard steels cannot match. The forging process ensures these high-performance materials have the best possible internal structure. They are used for critical parts in sectors like aerospace, power generation, and specialized machinery.
Extreme Heat Resistance: They keep their strength and do not fail when working at very high temperatures (over 600°C).
Exceptional Wear Resistance: They are built to resist extreme rubbing wear or heavy impact for a long time (e.g., high-speed tool steel).
Controlled Properties: We custom-make these steels to have very specific traits, such as unique electrical or magnetic responses.
Peak Reliability: Forging gives these expensive, high-alloy materials a flawless structure. This is a must for parts where failure is not an option.
Corrosion in Harsh Media: They resist specific, highly corrosive chemicals (like certain acids or molten salts) better than stainless steel.
Special Purpose Forged Steel Components by Simis Steel Forging Factory:
turbine discs and blades;
deep-sea drilling tools;
high-temperature fasteners;
rocket motor components;
non-magnetic shafts;
reactor vessel components;
specialized tool steel dies.
Special Purpose Forged Steel Categories Simis Uses:
High-Nickel Alloys (Superalloys):
Uses: Gas turbine components, furnace parts, and high-temperature pressure vessels.
Grades: Inconel, Waspaloy, Hastelloy.
Tool Steels (Hot Work / High Speed):
Uses: Forging dies, hot shear blades, and cutting tools that run at high temperatures.
Grades: H13, D2, M4.
Maraging Steels:
Uses: Parts needing ultra-high strength and good toughness with simple heat treatment (e.g., aerospace and defense).
Grades: C250, C300.
Non-Magnetic Steels:
Uses: Parts for mining and electrical gear where a magnetic field must be avoided.
Grades: High-Manganese Austenitic Steels.
Carbon Steel Forging
Forging carbon steel heats the metal until it's soft. Then, a hammer or press applies pressure to shape it. Forging greatly improves the grain structure. It removes inside flaws, boosting the steel's strength. This makes it ideal for critical parts that need high reliability and strength.
Superior Strength: Forging refines the grain and makes the metal denser. This results in better tensile strength, fatigue life, and impact toughness than cast or machined parts.
Flawless Inside: Forging removes internal flaws like holes and shrinkage spots found in castings. This ensures high reliability and safety.
Continuous Grain Flow: The grain structure follows the part's shape. This gives the best strength right where it's needed, improving resistance to breaking from stress or impact.
Cost-Effective for Big Jobs: For making many complex parts, forging is cheaper than cutting them from solid stock. Plus, it gives better strength.
Easy to Machine: Forged carbon steel machines well when it's been normalized or annealed. This allows for precise final shaping.
Forged Carbon Steel Parts from Simis Steel Forging Factory:
Car crankshafts and connecting rods;
gears and transmission shafts;
hand tools (wrenches, hammers);
construction machine parts;
railway axles and wheels;
industrial shafts and couplings.
Carbon Steel Forging Categories Simis Uses:
Low Carbon Steel Forgings (Carbon ≤ 0.25%):
Uses: General structural parts, car body parts, construction hardware, and case-hardened components.
Grades: SAE 1008, 1010, 1015; ASTM A668 Class A.
Medium Carbon Steel Forgings (Carbon 0.25% - 0.60%):
Uses: Car crankshafts, connecting rods, gears, axles, and strong structural parts.
Grades: SAE 1045, 1050; ASTM A668 Class D (C45).
High Carbon Steel Forgings (Carbon ≥ 0.60%):
Uses: Cutting tools, springs, strong wire, wear parts, and railway wheels.
Grades: SAE 1060, 1070, 1080; ASTM A668 Class G.
Free-Cutting Carbon Steel Forgings:
Uses: High-volume parts that need a lot of machining, like fasteners, fittings, and car parts.
Grades: SAE 1117, 1144; ASTM A668 Class C.
Stainless Steel Forging
Forging stainless steel shapes the hot alloy under high pressure. Stainless steel has chromium and nickel to stop rust. Forging makes the metal's inside structure much better. The final parts are very strong and resist rust, heat, and cold well. Forged stainless steel is the best choice for parts in bad, rusty environments.
Very Strong: It is stronger than casting or machining. It handles impact and repeated stress better.
Rust Resistant: The process removes surface and internal flaws. This helps the part fight corrosion.
Reliable: It has no holes or cracks inside. This makes it safe and durable.
Handles Heat: It keeps its strength and resists rust even at high temperatures.
Smooth Surface: The finished part has a good finish. This means less extra work is needed.
Forged Stainless Steel Components by Simis Steel Forging Factory:
high-pressure flanges and valves for oil and gas;
important marine parts;
surgical tools and medical implants;
food processing parts;
chemical tank components;
turbine blades.
Forged Stainless Steel Categories used by Simis Steel Forging Factory:
Austenitic Stainless Steel
Use: Good for chemical, food, and medical parts.
Grades: ASTM A182 F304, F316.
Martensitic Stainless Steel
Use: Good for strong tools and parts like surgical instruments.
Grades: ASTM A182 F410, F420.
Duplex Stainless Steel
Use: Good for tough places like offshore oil rigs and chemical plants.
Grades: ASTM A182 F51, F53.
Alloy Steel Forging
Forging alloy steel adds specific elements like nickel and chromium to carbon steel before shaping it. The metal is heated and then pressed into form. This process boosts the steel's strength, hardening ability, and performance in harsh conditions. Forged alloy steel offers a better strength-to-weight ratio than carbon steel. It is essential for critical jobs where carbon steel is not strong enough.
Customizable High Strength: We can add alloys to reach very high strength and hardness. We fine-tune this strength using special heat treatments.
Hardens Deeply: Elements like chromium help the steel harden evenly, even in very large parts. This is key for heavy, high-stress components.
Fights Wear and Fatigue: The improved structure fights rubbing wear and metal fatigue well. This is due to the refined grain and added elements.
Works in Extremes: Some grades stay strong in very high heat (red hardness) or keep their toughness in extreme cold. This meets the needs of aerospace and energy fields.
Flawless Inside: Forging removes internal flaws (like holes) to ensure maximum metal density and safety in all parts.
Forged Alloy Steel Parts from Simis Steel Forging Factory:
Turbine and rotor shafts;
high-performance gears and pinions;
heavy-duty axles;
aircraft landing gear parts;
high-pressure valve bodies for oil and gas;
specialized tools and dies.
Alloy Steel Forging Categories Simis Uses:
Chromium-Molybdenum (Cr-Mo) Steels:
Uses: Strong shafts, gears, tool joints, and parts needing good toughness in moderate heat.
Grades: AISI 4130, 4140, 4150.
Nickel-Chromium-Molybdenum (Ni-Cr-Mo) Steels:
Uses: Critical parts needing the highest strength, toughness, and fatigue life (e.g., aircraft gear and heavy crankshafts).
Grades: AISI 4340, 8620, 9310.
Bearing Steels (High Carbon Chromium):
Uses: Parts needing extreme hardness and long rolling fatigue life (e.g., bearings and races).
Grades: AISI 52100.
Boron-Alloyed Steel
Use: Good for fasteners and automotive parts that need good hardenability.
Grades: SAE 15B21, 15B30.
Special Purpose Forged Steel
Special purpose forged steel is designed for jobs with extreme demands. This includes high heat, high pressure, or special wear. These steels use complex alloys (like high nickel, cobalt, or tungsten) to achieve traits that standard steels cannot match. The forging process ensures these high-performance materials have the best possible internal structure. They are used for critical parts in sectors like aerospace, power generation, and specialized machinery.
Extreme Heat Resistance: They keep their strength and do not fail when working at very high temperatures (over 600°C).
Exceptional Wear Resistance: They are built to resist extreme rubbing wear or heavy impact for a long time (e.g., high-speed tool steel).
Controlled Properties: We custom-make these steels to have very specific traits, such as unique electrical or magnetic responses.
Peak Reliability: Forging gives these expensive, high-alloy materials a flawless structure. This is a must for parts where failure is not an option.
Corrosion in Harsh Media: They resist specific, highly corrosive chemicals (like certain acids or molten salts) better than stainless steel.
Special Purpose Forged Steel Components by Simis Steel Forging Factory:
turbine discs and blades;
deep-sea drilling tools;
high-temperature fasteners;
rocket motor components;
non-magnetic shafts;
reactor vessel components;
specialized tool steel dies.
Special Purpose Forged Steel Categories Simis Uses:
High-Nickel Alloys (Superalloys):
Uses: Gas turbine components, furnace parts, and high-temperature pressure vessels.
Grades: Inconel, Waspaloy, Hastelloy.
Tool Steels (Hot Work / High Speed):
Uses: Forging dies, hot shear blades, and cutting tools that run at high temperatures.
Grades: H13, D2, M4.
Maraging Steels:
Uses: Parts needing ultra-high strength and good toughness with simple heat treatment (e.g., aerospace and defense).
Grades: C250, C300.
Non-Magnetic Steels:
Uses: Parts for mining and electrical gear where a magnetic field must be avoided.
Grades: High-Manganese Austenitic Steels.
Application Of Steel Forgings
Custom Steel Forgings by Simis Forging Factory
Steel Forging Company's Custom Steps
Confirm customization requirements
Design Review and Samples
Simis engineers first check the 3D and plane drawings. This makes sure your design is ready for the forging process. If you have a sample part, we can make the new parts based on that sample.
Define Part Requirements
We confirm what the part needs to do. This includes things like its strength, hardness, wear, and rust resistance. We also set the exact size, tolerance, and finish quality needed for the forged part.
Confirm Forging Material
Our engineers help you pick the right steel material. This choice depends on where the part will be used and your technical needs. We give advice based on material cost, strength, and resistance to wear or rust.
Choose the Forging Process
We select the best forging process for your part. We base this choice on your price goal, the part’s shape, its required dimensional accuracy, and the material.
Make Dies and Samples
We build the forging dies (molds) using your approved drawings or samples. Then, we shape the steel material through the chosen process to produce the first batch of samples.
Full Sample Inspection
The finished samples go through a full check. This confirms they meet all design standards and your quality demands. We give you reports covering size and tolerance inspection, performance testing, chemical composition analysis, and non-destructive testing.
Production and quality control
7. Mass Production
After you check and approve the sample, we start the mass production plan. We get all the materials ready based on your order. We use the exact same forging equipment and process as we did for the sample. This makes sure every single part we make is the same.
8. Quality Control During Production
We run tight quality checks while making the parts. We pull parts for checks often during the process. We test their size, look, and strength. This ensures every batch of forged steel parts is consistent and meets your needs.
9. Final Product Quality Inspection
We use multiple inspectors for the final check. They do many tests on the finished product. These tests cover size accuracy, surface quality, and part strength. This step makes sure all forged steel parts meet your quality standards.
10. Packaging and Delivery
We securely package and ship all approved parts. We pick the right packaging to prevent damage during shipping. We also choose the best delivery method (air, sea, or land) to get your parts to you on time.
To order custom parts, please email us your design drawings and 3D models. Our team will review the detailed part parameters and the 3D model to provide you with an accurate quote.