Shaft forgings are manufactured through a process that involves shaping the shaft Forgings with localized compressive forces. The forging process initiates when a piece of steel is struck recurrently with a hammer or squeezed with a press. We have the inventory and skills to manufacture forged steel shafts out of carbon and alloy steel.

What is steel casting?

Molten steel ingots are poured into a casting mold that takes the rough shape of the item to be manufactured, cooled, and then shot blasted, or sand blasted to achieve a smooth surface. There is no grain flow during the casting process, and the item has no increased directional strength. It is the most cost-effective method of producing steel products, but the end product is not as strong or durable.

What is steel forging?

The steel preform is heated and positioned into upper and lower dies in the most frequently used technique for critical components. The heated metal is forced into the form of the 'die' under extreme pressure.

Unlike the 'cut' originated, the grain flow is directional and oriented to enhance strength/toughness (i.e., increases steel flexibility and impact resistance). A forged item is less prone to fatigue and stress because no grain ends are exposed.

Casting vs. forged fittings:

A cast fitting is produced by pouring molten metal into a mold of the desired shape. Because the grain flow of the heavy steel piece is changed to correspond to the structure of the part in the die, forged steel fittings are tougher and more credible than castings. As a result, forging ensures that the finished part's structure and composition are consistent.

The refinement is held by the thermal cycle and deformation process, which strengthens the last part regarding internal working pressure, external impact, and shear strength.

What're the advantages of forging over casting?

• A forging is structurally stronger than a casting because of its tight grain structure.

• Forgings, unlike castings, are not prone to pores, cold pour issues, porosity, or shrinkage.

• Castings generally necessitate more costly alloys to achieve the high strength needed for most fittings.

• Compared to castings, the tight grain structure of forgings provides more wear resistance and is less likely to become brittle, letting the forged fitting withstand very high pressures and more severe conditions and have a longer service life.

In brief, forged steel fittings outlast castings and are typically less expensive in similar applications. You can also use our quality closed die forgings products for your industrial requirements.

How Does Steel Forging Improve Strength?

• Forging results in predictable and homogeneous grain structure and flow characteristics, increasing directional strength.

• Forging eradicates internal voids/gas pockets that weaken metal components, resulting in improved chemical homogeneity and structural strength.

• Forging ensures proper grain flow orientation, increasing fatigue resistance and impact strength.

In conclusion, the steel forging process adds approximately 30% more strength/toughness to the original billet it was made from. Forging has much higher initial tooling costs than steel casting, so it must be manufactured in large quantities to 'break even' on the initial expense. However, given the benefits of steel forging, this is a cost-effective method for high-volume production.

KDK Forging Co. ensures that we provide our customers with the correct length and diameter so that the intent of the shaft is met competently. We understand the worth and significance of each material. Hence, our affordable shaft forgings will be used properly in various industrial applications.