Today, manufacturers frequently forge brass and copper alloys. Although the specific type of forging depends upon the particular composition of the metal, generally these alloys lend themselves to cold, warm and hot forging techniques. The process of forging enables these metals to display strength and superb physical properties. During forging, manufacturers typically use a set of dies to form and shape metal into desired dimensions.
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Forging readily permits the creation of copper bars, rods, wires, sheets and more. Some common copper alloys include copper nickel, naval brass, aluminum bronze, chromium copper and chromium zirconium copper. Most brass alloys include both copper and zinc. The level of zinc will influence the forging process and the strength and ductility of the final products.
Today, manufacturers enjoy access to a myriad of different copper and brass alloys. They may select individual metals to use in copper and brass alloy forgings based upon their properties and intended applications.
Some metals, such as silver, exhibit superb antibacterial characteristics. Copper displays antimicrobial properties against some types of bacteria. These properties may influence a manufacturer&#;s selection of alloys. Copper maintains excellent electrical conductivity. Copper and brass typically exhibit high electrical and thermal conductivity, high ductility, excellent joining and plating properties, and corrosion resistance. Non-magnetic and non-sparking, these metals work well for machining purposes also.
Although vulnerable to sulfides, copper and copper alloys generally display resistance to corrosion caused by steam. Tough, highly ductile and malleable, manufacturers can draw wire, form tubes and conduct deep drawing and spinning using copper.
Many brass alloys include both copper and zinc. Zinc enhances the strength and versatility of brass alloys, which may benefit from heat treatments such as tempering and annealing in order to reduce susceptibility to stress corrosion cracking.
Copper and brass forgings offer distinct advantages to manufacturers. Some of the general benefits include:
&#; superior mechanical characteristics
&#; high density;
&#; dimensional accuracy;
&#; repeatability;
&#; excellent surface finishes
Forging will augment and enhance many of the intrinsic properties of brass and copper. For instance, forging may increase the working of these metals. Work may occur both during forging and also during the process of rod extrusion. The net result of multiple working usually involves increases in the strength and the impact and abrasion resistance properties of brass and copper.
Additionally, higher leak resistance may occur as forging density increases. Fewer variations in dimensions also occur during extensive forging processes.
Maximum cost savings often result when manufacturers rely on mass production of copper and brass forgings. Grappling with specific design issues may warrant small production runs of copper alloy forgings. For example, these types of limited runs may permit manufacturers to address close tolerances, non-symmetrical shapes and leak integrity issues cost-effectively before seeking larger production runs.
Today, manufacturers produce brass and copper forgings using a variety of brass and copper alloys. Foundries rely upon cold, warm or hot forging processes. The desired qualities of the finished metal part usually determine the types of production processes employed.
Manufacturers can use cold forming to work with most alloys of brass and copper. The ability to use cold forging depends upon the chemical composition of the alloy, and the metal&#;s annealed properties. Both reliable and cost-effective, cold forging may improve a metal part&#;s hardness and ductility. The use of cold forging usually involves cost savings. It may increase the toughness of a component, and permit the creation of excellent dimensional accuracy and a high surface quality in a finished part. Highly productive production runs sometimes use this process, which may include activities such as cold drawing, cold heading, bending and more in order to produce diverse shapes.
Brass and copper alloys display versatile properties. Manufacturers often seek to shape and work these materials in a variety of ways. During the process of warm forging, a manufacturer uses an elevated temperature to forge copper and brass. The temperature range remains lower than during hot forging, but does rise to a level above room temperature. In general, utilizing warm (as opposed to hot) forging assists tooling life, individual part tolerance ranges and sometimes, surface finishes.
A process called &#;hot forging&#; enables the production of many brass and copper parts. In this process, metals undergo plastic deformation at high temperatures. Manufacturers use this process to forge complex shapes unavailable through the processes of cold or warm forging. Hot forged copper and brass alloys display increased ductility. They also typically demonstrate an excellent surface quality. The process of hot forging proves especially useful in the creation of custom-designed brass and copper forged parts.
Why do customers choose Bunty LLC at their source for high quality copper and brass forgings? We furnish assistance at every stage in the process of creating excellent custom-designed forgings. Our goal remains complete customer satisfaction.
By selecting Bunty LLC, you&#;ll obtain an outstanding selection of brass and copper alloys to use in the creation of metal components meeting your specifications. We support a wide variety of applications.
Additionally, our well-equipped manufacturing facility enables us to draw upon high-precision equipment to assist the creation of forgings meeting customer requirements. We&#;ll complete projects using modern machinery. We perform rigorous quality control procedures to help maintain part consistency.
We take great pride in supplying high quality customized brass and copper forgings at competitive prices. Call us to obtain additional information, or request a quote via the convenient website information request form!
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A forging manufacturer offers cost-effective opportunities to businesses in many industries. They produce strong and reliable products, and can customize each component to help businesses meet specific goals.
Keep reading to learn more about what forging is and why you should consider working with a professional forging manufacturer.
What Is Forging?The forging process involves deforming and manipulating metals into finished products, oftentimes using heat to aid in material movement.
Types of Forging ProcessesTypically, forging manufacturers use one of four methods to produce forged products. The practices include impression die forging, cold forging, open-die forging, and seamless rolled ring forging. Each process delivers unique benefits when applied to specific materials.
Impression DieImpression die forging is a preferred method for steel, aluminum, titanium, and other alloys. These forgings are often made using hydraulic presses, mechanical presses, and either power-driven or gravity drop hammers.
This forging process is well-known for its ability to create seemingly limitless 3D possibilities. Other benefits of this process include:
Reduced Waste
Improved Production Rates
Improved Impact Resistance
Better Strength-to-Weight Ratios
While the majority of hot-forging work is conducted at temperatures of around 2,300 degrees Fahrenheit (for steel), cold forging is different. This unique process involves methods like extrusion, heading, or upsetting, and is conducted at room temperature through compressive force.
Though it can be done on tough materials, relatively soft metals, including gold, silver, copper, and brass benefit the most from this technique. Benefits of cold forging include:
More Refined Surface Finishes
Cost-Effective
Minimal to Zero Waste
Longevity
Improved Tensile Strength
A manufacturer may also choose this method to design automotive parts involved with steering and suspension. It remains an economical choice across a wide range of industries.
Open-DieThis method produces forgings as light as a few pounds to upwards of 150 tons. Its name comes from the fact that the workpiece is not laterally confined by the walls of an impression, as would be in closed-die or impression-die forging. The practice allows a forging manufacturer to create an exponentially wide array of shapes and sizes. The top benefits of the open-die process include:
Enhanced Fatigue Resistance
Increased Strength
Durability
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Finer Metal Grain Sizes
This forging process utilizes striking or forming tools instead of enclosed impressions, which is why it&#;s a preferred method when manufacturing very large components.
Seamless Rolled RingThe seamless rolled ring is a popular forging method for manufacturing mining, aerospace, energy, and heavy-duty components. This method involves piercing a hole in a large round piece of metal and compressing the inner and outer diameters between forming rollers as it is spun. The final products can range from mere inches to upwards of 30 feet. The seamless rolled ring process delivers the following benefits:
Superior Structural Integrity
Fewer Weaknesses
Forged rings remain a preferred choice when creating torque- and pressure-resistant components. The commonly used materials include carbon and alloy steels and non-ferrous materials.
Benefits of ForgingMetal-based products crafted by a forging manufacturer are typically superior to those made through casting or machining processes. That&#;s largely because the original grain flow from the steel making process is retained, optimized, or improved when forming a desired shape and size. Other reasons to opt for professional forging include:
Stronger Products
More Reliable & Commercially Safe Components
Custom Solutions & Innovative Designs
Consistent & Improved Metallurgical Properties
Forging manufacturers must meet the demands of industries that need solid and reliable solutions. Some of the industries that rely on forging, include:
AgriculturalThe agricultural sector has significant forging needs. Farming components, including combine fingers, sickle heads, U-joins, and tie rods are robustly forged parts.
ConstructionArchitects and contractors are tasked with finding innovative solutions for extreme load-bearing structures. Forging manufacturers remain the go-to solution when other metallurgical methods fall short.
AutomotiveMany automotive companies, including household names like Ford and Chevrolet, rely on forging manufacturing for ball joint housings, exhaust flanges, suspension parts, and much more.
Commercial Truck & TransportationClass 8 commercial motor vehicles require the strongest and most reliable metal parts possible. A tractor-trailer can weigh upwards of 80,000 pounds when hauling loads&#;that&#;s why torque-resistant forged parts are critical to safety.
DefenseThe brave men and women who serve our country deserve the enhanced protection of forged metal products. Forging manufacturers provide the metal parts that help harden our country&#;s defenses.
MarineMarine hardware must stand up to severe weather, the effects of saltwater, and pressure. That&#;s why shipwrights and boating repair facilities rely on manufacturers to produce forged bolts, spindles, bearing plates, and watertight door hardware.
Mining & ForestryThe heavy-duty equipment required for mining and forestry operations must withstand excessive force and hard impacts. If rock tools, hammerheads, and block cutters falter, everyday people could be placed in harm&#;s way.
Power TransmissionDriveshafts incur among the highest torque rates on a car, truck, or SUV. Auto manufacturers rely on only the most reliable power transmission parts possible to ensure driver safety. Forging processes enhance parts strength and make vehicles roadworthy.
RailroadAmerica&#;s supply chains rely on intermodal transportation, and our railroads join truckers in delivering goods and materials to communities. Forged metal parts, including boxcar handle brakes, locomotive pins, and grab irons are central to keeping trains running on time.
Common Duties of a Forging ManufacturerA forging manufacturer has one primary duty&#;to deliver the highest quality parts and solutions possible. Meeting that responsibility requires years of experience, expertise in wide-reaching forging processes, and a daily commitment to excellence. Other capabilities of a forging manufacturer may include heat treatment, machining, coating, and more.
What to Look for in a Forging ManufacturerIf you need durable metal products or innovative solutions, it&#;s crucial to conduct research before working with a manufacturer. Consider an organization&#;s years of experience, certifications, record for on-time deliveries, and their ability to bring creative solutions to the table. Additionally, be sure they do not outsource their work to a foreign company.
Why Choose Trenton Forging?Trenton Forging has been an industry leader since . As an American forging company, we produce all of our parts in-house, right here in the United States. Our commitment to quality is the reason why we have a long list of satisfied clients. We provide a wide array of services, including impression-die forging, machining, and coating, and assist clients in many industries.
Request a Quote TodayIf you&#;re looking for innovative solutions, contact Trenton Forging. We&#;ve been a trusted forging manufacturer for many years and take pride in our exceptional capabilities. Call us at (734) 672- or fill out our online form today to learn more about what we do, or to request a quote.
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