Integrated Engineering Solutions
Class-leading metal, forgings, machining direct from the mill
FORGINGS - WROUGHT ALLOY CREATION
Creating alloys is a complex business requiring precise control over a wide range of complex variables that need to be understood. We at Copper Alloys+ have a deep understanding of these complex processes.
Wrought alloys start life in the foundry by being cast using our special vertical continuous casting process, or by being cast into weighty forging ingots. The forging ingots are cast using our Quiescent Teaming System, specially designed to fill ingot moulds with non-turbulent flow, avoiding the formation of harmful metal oxide films and inclusions. Solidification is controlled to ensure a good macrostructure free from secondary shrinkage and sufficient ingot top discard to fully remove the primary pipe which is the result of feeding solidification contraction.
3 BENEFITS OF FORGINGS
Quicker & on-time delivery; risk of non-delivery reduced
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High integrity - actual material properties are reported
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Enhanced resistance to corrosion and general performance
3 LIMITATIONS OF CASTINGS
Actual component properties are unknown as reported properties come from separately cast test piece
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Prone to metallurgical defects
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No efficient method of volumetric inspection
2 MYTHS ABOUT FORGINGS
Forgings are more expensive
Due to the reliability of the production process, zero tooling costs and scalability of production, components made from forgings can be lower cost
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Complicated shapes have to be castings
With modern CNC machining techniques, it is possible to machine surprisingly complicated components from solid blocks of forged material. A good example is this nickel-aluminium bronze forging, that was machined from solid. Previously it was two castings welded together.