Closed die hot forging is a process where heated metal is shaped into strong, precise parts using custom dies. At Cornell Forge, we are a family-owned business with over 90 years of experience producing high-quality, complex forged components. Focusing solely on closed die hot forging, we deliver reliable forged parts for industries like energy, automotive, aerospace, oil and gas, and more.

Learn more about the unique benefits and applications of this technique, as well as the steps of our robust closed die hot forging process.

Why Choose Closed Die Hot Forging? And What are the Benefits?

If you’re working on a high-volume project that needs parts with serious strength, closed die hot forging is an ideal option. In this method, metals undergo metallurgical recrystallization, a beneficial realignment of the metal’s grain structure. Rather than being melted, the metal experiences compressive forces that alter the grain to follow the flow of the final product. With a more uniform grain structure, the finished forged part is denser, stronger, and more durable than casted or machined parts.

Closed die hot forging is compatible with a wide range of part weights, from several ounces up to 60,000 pounds. The technique is suitable for stainless steel, copper, nickel, and many other common metals. Closed die hot forging can produce tight-tolerance components that require little to no machining, unlike open die forging.

Key benefits of closed die hot forging include:

  • High strength. The process repeatedly alters the metal’s grain flow, resulting in final parts with high impact strength and structural integrity.
  • Cost efficiency. Because it requires little to no machining and produces consistent quality, closed die hot forging helps lower overall production costs. If a cast part exhibits excessive porosity, it is scrapped and remade, contributing to higher labor and material costs. With their greater consistency and durability, forged parts eliminate these risks.
  • Tight tolerances. The precision of closed die forging reduces waste, ensuring that parts are produced to exact specifications.
  • Low porosity. Other manufacturing methods like casting can produce metal parts with cold pour or shrinkage issues, porosity, or cavities. Closed die hot forging results in exceptional consistency of quality, creating low-porosity parts with better surface finishes, uniformity, and long-term durability.
  • Manufacturing flexibility. Whether you need custom shapes or intricate designs, closed die hot forging can handle a wide range of specifications.

Cornell Forge’s Hot Forging Process & Key Considerations

At Cornell Forge, our hot forging process optimizes precision and strength. Our forging experts manage the following three steps carefully so that every part meets the highest quality standards:

  1. Heating. We start by heating the metal in a furnace until it becomes flexible and easy to shape. The exact temperature depends on the type of material we’re working with.
  2. Deformation. Once the metal is ready, we place it into a custom-made die comprised of two halves shaped with a precut profile of the desired component. The die is heated as the two halves move toward each other to cover the workpiece. Under intense pressure, the raw material is shaped into the desired form, and any remaining flash is removed.
  3. Cooling. After forging, we cool the part under controlled conditions to prevent any defects as a result of uneven or accelerated cooling.

We consider the following key factors throughout the process:

  • Custom dies. Each part we make requires a custom die to get the exact shape and design needed.
  • Cooling temperatures. Cooling is carefully managed to preserve the strength and structure of the part.
  • Dimensions and tolerances. Our expertise in this type of hot forging process means we can consistently produce components with exact dimensions and tight tolerances.

Hot Forging Applications

Closed die hot forging is incredibly versatile, making it the go-to choice for many industries that need strong, reliable parts. Here’s how different sectors benefit from the process:

  • Automotive. Hot forging is used to make crucial parts like connecting rods, beams, and shafts that need to handle high stress.
  • Construction. It’s perfect for creating heavy-duty machinery components that can withstand the harsh working environments of construction sites.
  • Mining. Ground foundation bits, auger bits, and other mining equipment benefit from the strength and durability of forged parts.
  • Forestry. Mulcher teeth, flail hammer blades, tub grinder teeth, and other cutting tools are forged to stay sharp and last longer under tough forestry conditions.
  • Agriculture. Spike harrow teeth, gears, shafts, and tie rod ends are hot forged to hold up amid the demands of agricultural environments.
  • Oilfield. Elbows, hammer union nuts, and tees used in oil and gas industries require the strength and precision that closed die hot forging offers.
  • Lifting and rigging. Shackles, hooks, and welds need to be strong and reliable, and hot forging makes sure they can handle heavy loads without failure.

Partner With Cornell Forge for Your Closed Die Hot Forging Needs

When you choose closed die hot forging, you’ll benefit from components with superior strength, precision, and cost savings. At Cornell Forge, we’re dedicated to delivering high-performance forged parts that meet the strictest industry standards. Whether you need automotive parts or complex oilfield components, our expertise ensures you’ll get a reliable, high quality solution made specifically for your needs.

We specialize in custom steel parts made of premium-quality steel alloys, including stainless steel. Our team also offers heat treatment, assembly, and other value-added services to deliver a complete solution.

Contact us today or request a quote to see how our closed die hot forging services can support your project.