Contact Us: 1-440-250-1900

Open Die Forging Aerospace Application

Have you ever heard of the term “smith forging”? Before all the advancements in tools and technology, forging was performed by a smith using an anvil and hammer to produce and create forged metal – hence, the term. Smith forging, commonly known as open die forging, is a process that involves a hammer striking and deforming a workpiece securely attached to a stationary anvil.

What is Open Die Forging?

Why do Aerospace Companies Prefer Open Die Forging?

The Basics

Open die forging involves the process of forging alloys without having to enclose the workpiece throughout the procedure. In this process, it is required that the operator knows the proper position and orientation of the workpiece to achieve the desired shape.

The dies or surfaces are normally flat in shape. However, there are instances when dies with a specific shape are used for specialized forging. For instance, a die may have a convex, concave, or round surface. It may also be a cut-off tool or a device to form holes.

Advantages of Open Die Forging

Aerospace companies consider the advantages of open die forging before choosing this metalworking process to produce aerospace parts and components. Below are the advantages:

  • Superior strength
  • Better-quality grain size
  • Constant grain flow
  • Enhanced microstructure
  • Improved fatigue resistance
  • Reduced chance of voids

Progressive open die forging techniques are capable of creating multiple shapes notwithstanding the large parts and components used. Simple shapes like rounds, ingots, and bars are easier to produce because of the constant grain flow and improved fatigue resistance.

The most common subjects used for smith forging are steel and related alloys. Nonetheless, other metals can be shaped as desired. These metals include titanium, nickel, and copper alloys.

Industrial or Commercial Aerospace Parts

The following are the parts and components used by aerospace industries that were produced and forged through an open die forging method:

  • Shafts
  • Seamless rolled rings (bearings)
  • Rotor/Propeller Parts
  • Landing gear components
  • Flat bar
  • Flanges
  • Disks

What is Open Die Forging?

Learn More About Open Die Forging Applications

At Ferralloy Inc., our commitment to the industrial and commercial sectors has made us grow bigger. We make sure to give more importance to the quality and satisfaction of our clients. Contact us today to speak with an expert!

Characteristics of Open Die Forging

Open die forging is a type of drop forging technique of deforming a metal according to the desired shape. Without any limitation, it can utilize pressure and power inflicted. Some experts even call it free forging since the process involves fewer restrictions. 

what are forged rolled rings?

Features of Open Die Forging

Simple Production Equipment

One of the most notable characteristics of open forging is that it requires only the necessary production equipment. Because of this, the production cost is lowered. In contrast with other forging processes, open die forging bar any possible defects such as porosity, gas holes, or shrinkage. 

High Mechanical Properties

Unlike closed die forging, this type of technique involves basic shaping and flexible operation. Because it uses higher mechanical properties, open forging always acts as an essential part of heavy-duty machinery.  

Manual Operation

Nowadays, forging techniques are controlled by manual operations. Another feature why industries purchase equipment made through an open die forging process is that manual operations hold the dimensions and net near shapes. Hence, the accuracy of product sizes has become relatively low. 

Main Equipment Used

Open forging primarily uses two main types of equipment. These are the hydraulic press and forging hammer. To be more specific, the steam hammer and air hammer are used. Also, a hydraulic press is used to reshape the metals into its desired form. It uses static pressure produced by a liquid solution. 


Open forging uses both machines and labor to produce quality materials that are worth the investment. Because it uses work, the production cost decreases. Hence, open forging is a metal forging technique that’s suitable for single and accurate production.

what is closed die forging?

Learn More About the Open Die Forging Process

Open die forging involves numerous processes such as welding, cutting, mismatch, torsion, bending, etc. Also, it uses a technique called elongation. It is a process commonly performed to produce components for rod and shaft parts. 

If you want to know more about the forging applications and which product to choose, experts at Ferralloy Inc. will help you! Contact our experts today through this link!

What are the Best Applications for Open Die Forging?

Open die forging is known to have the most demanding applications in the metal industry. It is used because of the several features it contributes, such as near net shape materials and improved structural integrity. Read on to know the typical open die forging applications.

what is steel forgings?

Applications and Benefits of Open Die Forging


Forging metals is not an easy job. However, experts found a way to make things more accessible without compromising the quantity of the materials. Forging is commonly used in industries like:

  • Shipbuilding
  • Defense
  • Infrastructure and Construction
  • Aerospace
  • Power Transmission and Gearing
  • Metal Processing
  • And More

Types of Applications

Forging is best used in large and bulky pieces with a short run purpose. These generally consist of custom forged shapes, flanges, hubs, discs, cylinders, shafts, blocks, and forged bars. However, it is popularly used in bespoke designed and single run products.


The most common advantage of forging is of exceptional strength. It can create hard-wearing materials without compromising the quality of a surface finish. Aside from outstanding durability, forging is also known to produce materials with more exceptional grain size and better fatigue resistance. Because of its better resistance level, metals are not prone to wear and tear.

Additionally, the use of open die forging allows the manufacturer to achieve lesser material waste. It is also more economical because fewer materials are used to make its forging goal. Moreso, this type of forging process includes a shaping process that decreases the presence of voids in the finished products. 

Materials Used

Forging uses a wide variety of forging materials. The materials used will depend on the expected finished product. Most manufacturers use bronze, nickel, copper, aluminum, and tool steel. While others use titanium, Inconel, stainless steel, alloy steel, and carbon steel. 

what are forged rolled rings?

Looking for Quality Open Die Forging Material?

At Ferralloy Inc., our reliable team is here to help you find exactly what you are looking for. Reach out to one of our professionals today by visiting our website or giving us a call.

What are the Advancements in Open Die Forging?

A lot of industries know by now that open die forging can measurably decrease the costs of materials, as it needs less starting stock to create several part shapes. Hence, less machining is required to achieve a specific metal component with the added assistance of lesser lead time.

Likewise, it has the ability to reduce wear and tear on the apparatus, tool, or equipment. Fundamentally, most open die forgings are specifically made one at a time, giving every purchaser the option to buy one or hundreds of materials as needed.

where is the best open die forging?

What are the Developments in Open Die Forging?

Improved Structural Integrity

An open die forging often provides weld-free parts formed and manufactured with cleaner and forging-quality materials. One of the developments in this type of forging is that it can now eliminate rejections to achieve a fully improved structural integrity.

Using a slightly different forging process, the same material can be produced from several varieties and sizes of starting billets or ingots. Through this process, a vast range of inventoried grades are created. It only shows that because of this flexibility, any parts or geometry can be produced economically, reasonably, and quickly.

Near Net Shape or Size

Although open die forging is commonly known to produce near net shape or size, advancements in this aspect allow it to create even precise and durable parts. Because every part of the forging process employs forge tooling is numerous ways to decrease the machining process time and input material, a good quality component is produced.

Experts know that tooling is the foundation for a perfect impression forging. However, this application is ideal only when the process involves a high quantity of repeatable products. With open die forging, the tolerances achieved because of advancements in technologies provide less machining requirements to acquire finished sizes and shapes.

Ultimate Solution in Custom Designs

Open die forging is also famous for being the ultimate preference in custom designs. Because it is flexible enough to the point that it is easy to achieve near net shapes and sizes, it becomes even easier to produce custom-designed metal components.

where is the best place to get open die forging?

Where to Get Open Die Forgings?

Are you planning to purchase quality open die forgings? If so, contact Ferralloy Inc. today! Our team is highly trained to help you find your needs.

Open Die Forging Versus Closed Die Forging

Forging is used in a variation of industries for things like oilfield equipment, automotive, agricultural machinery, and construction machines. When it comes to forgings, there are two main types – closed die and open die forging. Hence, it is essential to know the difference between the two types.

who offers the best castings investment? 

Difference Between Open Die and Closed Die Forgings

What are Open Die and Closed Die Forgings?

Closed die forging is commonly known as impression forging. It uses pressure to compress a piece of metal in order to fill an enclosed die impression. Likewise, it includes the use of a medium frequency induction heating furnace for applying heat to the metal until the desired shape is achieved.

In contrast, open die forging is sometimes called free forging. The open die forging process includes the placement of a piece of metal between several dies that don’t completely close the metal. Through a variety of movements, the dies hammer and stamp the material to alter its dimensions until the necessary shape is achieved.

Process Involved

With open die forging, colossal compressive forces are levied by the unceasing strike of a forging hammer to distort the metal billets. Unlike closed die forging, the open die process is significantly simpler. For closed die forging, the molding dies are first precision machined. The metal bars are then attached to between upper and lower dies and forged to any shapes needed. As a result, closed die forging is a net shape or near the net shape process. 


As open die forging does not include a fixed die size, this method works best for creating larger and heavier metal components that don’t require much machining to produce ultra-finished products. Amongst these hefty components are shafts and rollers that are used in railways. On the other hand, closed die forging is perfect for applications that need a high degree of precision such as automotive parts or forged fittings.

who offers steel castings?

Are You Looking for Open Die Forging?

At Ferralloy, we have the forgings you require for your next project. Whether it’s open die or closed die, we have the parts you need. Contact us today to know more.

Open Die Forging | What Hybrid Forging is All About

When you use open die forging is combined with closed die forging in your tailored forging process, you can optimize time and cost savings.

How Hybrid Forging Works

In order to move material more efficiently, hybrid forgers can use less tonnage in a prescribed manner instead of pushing 100% of the material’s surface area. This is made possible by the tooling and mechanics of the process. When it comes to closed die forging, 100% of the workpiece must be manipulated at the same time. Since it ultimately comes down to pounds per square inch, the hybrid forging process is able to produce larger and more complex components on the open die press. Aside from this, more efficient use of tooling and investment dollars can also be expected. Furthermore, the hybrid forging process allows you to quickly and effectively change the tool design than with casting molds or closed die impression.

Hybrid Forging Offers Enormous Benefits

Hybrid forging delivers great manufacturing, economic, and quality advantages compared to alternative metalworking processes. You’ll need to look into the part’s structural strength, impact strength, and directional strength. Aside from the fact that hybrid forging provides structural integrity that other metalworking processes fail to match, it also eliminates gas pockets and internal voids that produces weak metal parts. As it disperses the segregation of non-metallics, the hybrid forging process can provide you with excellent chemical uniformity.

Strength is Key

When it comes to the aspect of impact strength, the hybrid forging technique can produce components that can meet any load, stress, or impact requirement. Maximum impact strength and fatigue resistance can be met due to the proper grain flow orientation. In terms of impact directional strength, hybrid forging produces uniform and predictable grain size and flow characteristics. Porosity is also eliminated because the forging stock is pre-worked to refine the ingot’s dendritic structure.

who offers open die forging?

Do You Need More Information About Closed Die and Open Die Forging?

If you want to know more about closed die and open die forging, contact Ferralloy, Inc. today.

Open Die Forging | The Basics of Drop Forging

If you’ve ever wondered how modern forging facilities manage to manipulate metal into forged parts, then you’ll need to learn about the basics of drop forging (open die forging or closed die forging).

What is Drop Forging?

This process involves dropping a hammer onto the metal to mold it into the distinctly-shaped surfaces called dies that come in contact with the metal. Drop forging can either be open die forging or closed die forging.

Open Die Forging

Also called smith forging, this uses a hammer to strike and deform a metal that’s placed on a stationary anvil. Since this type of drop forging doesn’t completely confine the metal in the dies, the molten material flows in the areas where it’s not in contact with the dies. Therefore, it’s the operator’s job to position the metal until the desired shape is achieved. Open die forging is great for creating simple, large or customized metal components.

Closed Die Forging

Known as impression-die forging, it involves dropping a hammer onto the metal that is placed in a die and is attached to an anvil. The hammer comes in contact with the metal in quick successions until the excess metal is pushed out from the cavities of the die. This results in a flash that’s stronger and cools faster than the metal in the die. The flash is removed before the metal is moved through a series of cavities in a specific die.

who offers the best open die forging?

Need More Information About Open Die Forging and Closed Die Forging?

Ferralloy, Inc. are experts of open die forging and closed die forging. For more information, contact us today.

Open Die Forging | Facts About Open Die Forging

You’re probably aware that open die forging is a type of hot forging that’s commonly used to create bigger and simpler components in weights that range from a few pounds to over thousands of pounds. However, did you know that open die forgings are known to exhibit soundness, durability, high strength, homogeneity, and flow line characteristics?

The Nature of Open Die Forging

In case you’re wondering about how the open die forging process works, it’s performed between two flat dies that don’t have any impression made in them. Furthermore, forging the metal into the desired shape is heavily reliant on the movement of the workpiece. Depending on the forging shop’s capabilities, the size of the original stock limits the size of the open die forgings.

Materials that are Commonly Used for Open Die Forging

Although the open die process is capable of forging various types of metals, among the most common materials used are alloy steel, carbon steel, stainless steel, Inconel, copper alloy, and high-temperature alloy.

The Benefits of Using the Open Die Forging Process

If you want to create products that are characterized by superior strength and durability compared to products that are either machined or welded, you’ll be better off with open die forging. It has this ability to change and form the metal into your desired shape while breaking up the cast structure and producing finer grains. Aside from this, it improves mechanical properties because it consolidates low-density areas, gas porosity, and micro-shrinkage while enhancing the density and aligning the grain flow. If you work with advanced forging shops, you can produce custom metal parts with unique shapes.

what is open die forging?

Looking to Find Products that are Created with Open Die Forging?

You can trust Ferralloy, Inc. to provide you with superior products that are created with open die forging. Our top-quality forgings are guaranteed to meet your needs, regardless of the specifications of your subsystem or product. Contact us today!

Open Die Forging | FAQs About Open Die Forging

If you’re looking to find answers to your questions about open die forging, then you’ve come to the right place. For you to understand why you should buy metal forgings, let’s take a closer look at this type of process.

What is Forging?

Forging refers to the process involving the shaping of metal by applying compressive impact force by hand or certain mechanical manipulators after this has been heated.

What is Open Die Forging?

The open die forging process involves the shaping of hot metal parts through the use of net shape dies. Forgings of this type can be forged from a few pounds to over a hundred tons and over 80 feet long.

What are the Common Forging Products?

The process of open die forging typically produces round, rectangular, square, and hexagonal bars, beams, as well as other basic shapes. Common products formed include hubs, spindles, step shafts, mandrel, metal shells, pierced blanks, and simple pancakes forgings.

What are the Advantages of Forging?

One of the advantages of open die forging is the fact that it produces forging that has unique physical properties because the metal’s physical properties are enhanced and improved during the forging process. This means that its density is increased as its grain structure is being refined – both contribute to the metal’s overall strength. Furthermore, the metal’s grain flow is altered in such a way that it counteracts, accepts, as well as neutralizes a completed part’s or assembly’s stress load burden.

Where can I get open die forging?

Looking for More Information About Open Die Forging?

To get further details about open die forging, contact Ferralloy, Inc. today! We are here to help you find exactly what you are looking for. Reach out to one of our professionals today by visiting our website or giving us a call.

Open Die Forging | Closed Die Forging vs. Open Die Forging

The forging industry has come a long way from using inefficient processes and antiquated applications. Today, we see forging engineering in various industries including machinery, construction, automotive, agricultural, oilfield equipment, and so much more. Although there are numerous options for metal deformation using the forging concept, the most widely-applied processes are closed and Open Die Forging.


The Difference Between Closed and Open Die Forging


  • Closed die forging is also called impression die forging. It’s a process that involves the compression of a piece of metal under high pressure in order to fill an enclosed die impression for the required shapes. Sometimes, a second forging operation is needed to achieve the shapes’ proper dimensions. Among the factors that determine the cost of a closed die forged part are the type of material, the need for heat treatment, and the tightness of tolerances.


In terms of application, closed die forging is commonly used for small critical parts such as forged fittings, forged automotive parts, forged lifting and rigging hardware, etc. because of its high precision. Its benefits include better surface finish, it requires little or no machining, no material limitation, cost-effective for large production runs, and the dimensions of net shapes and tighter tolerances are highly achievable.


  • Open die forging is also known as free forging or smith forging. It refers to the process of deforming a workpiece by placing it in between dies that are usually flat and don’t completely enclose the material. Through a series of continuous movements, the dies hammer the metal until the required shape is formed. This process is used for simple products in small quantities such as cylinders, rings, discs, and shafts.


This forging technique is found to be more appropriate for large parts in a number of tons. Examples of these parts include forged rollers, forged long shafts, and forged cylinders. The benefits of Open Die Forging include cost savings, minimal material waste, reduced chances of voids, reduced lead time, little or no tooling cost, finer grain size, continuous grain flow, longer part life, increased part strength, improved microstructure, and better fatigue resistance.

Open Die Forging

Ferroalloy is a reliable comprehensive engineering resource that offers total supply chain management to a diverse customer base on a global scale. If you want to gain a deeper insight between closed and Open Die Forging, contact us today.