Carbon Steel Forgings

carbon steel forgings

What Are Carbon Steel Forgings? Carbon steel forgings are forgings manufactured out of a steel alloy with a percentage of carbon typically up to about 1.2%, and only residual amounts of other elements except for those added for composition control.

The higher the levels of carbon in the steel alloy the lower the melting point. Custom forgings can include any number of alloys to alter the final characteristics. Some of the alloys found within carbon steel forgings may include:

  • Tungsten
  • Titanium
  • Nickel
  • Chromium
  • Zirconium
  • Cobalt

Forgings manufactured by forging suppliers offering forging services are used in automotive manufacturing, mining equipment, military applications and other industries. Thanks to the durability and custom components available, these affordable parts are competitive alternatives to castings, fabricated components and other manufacturing alternatives.

Carbon Steel Grades

What alloy is best for your carbon steel forgings? Compare common categories and specific grades to see how they can achieve your manufacturing tolerances and finished product requirements. When forging manufacturing whether utilizing the process of impression die forging, or closed die forging it is important to understand that carbon steel alloys can be divided into four categories:

  • Very high carbon: Between 0.96%-2.1% carbon content allows for extremely strong, but brittle, material. You need to handle these alloys with care due to its brittleness.
  • High carbon: Between 0.55%-0.95% carbon content and 0.30%-0.90% manganese content offers great shape memory and strength. This carbon steel is commonly used in wire and spring manufacturing.
  • Medium carbon: Between 0.29%-0.54% carbon and 0.60%-1.65% manganese offer ductility and strength. Choose medium carbon for its long-wearing properties.
  • Low carbon: Between 0.05%-0.25% carbon and up to 0.4% manganese is an affordable option. Commonly known as mild steel, low carbon steel is easy to shape and can be carburized to improve its surface strength.

After comparing these basic categories, it’s time to find the specific alloy that fits your steel forging requirements. Here are a few common alloys to consider that each offers their own pros and cons:

  • 8620 alloy steel: A ductile interior and hard outer surface make this chrome-nickel-moly steel a strong choice for carbon steel forgings.
  • A513 steel: Choose this steel for a high-strength material commonly used in DOM tubing. The high carbon content decreases its machinability and weldability, but it can be transformed into custom forgings by a leading forging company.
  • A366/1008 steel: High strength and good formability give this steel a good surface finish. It’s commonly used in cold-rolled steel sheet applications, but can be forged to create a strong product.
  • 12L14 free machining steel: Lead introduced into this alloy creates a very high machinability rate. Its strength is slightly lower than similar alloys due the use of lead, but it’s still stronger than 1018 steel.
  • 1144 steel: Also known as stress-proof-equivalent steel, 1144 has high strength and ductility. After machining, you can enjoy low warpage and distortion from this unique alloy.
  • 1018 mild steel: One of the most common mild steels available, this reasonably strong and ductile alloy is a low-cost option for your forgings. It’s cold-rolled, so it can have a better surface finish than A36 and other hot-rolled steels.

Advantages of Carbon Steel Forgings

forging services

Create custom carbon steel forgings to stay at the forefront of your industry. Compared with other manufacturing processes, forging offers a number of critical advantages:

  • Improved grain structure
  • Efficient production
  • High impact strength
  • Cost-effective processing

The grain structure of closed-die forgings makes it mechanically stronger than similar alloys that undergo different manufacturing processes. Depending on your application, you may be able to choose a lower-strength alloy and still achieve the same end result through forging.

Drop forged carbon steel from Trenton Forging can create a wide range of products. The size and shape capabilities of forging allow for this process to be used for a variety of industries. Once your forging company prepares the dies, you can enjoy fast-paced production to keep up with your manufacturing timeline.

The forging process creates a finished product with high levels of impact, load and stress resistance. These strength qualities are essential for heavy industry, automotive, agricultural and other industries.

Compare carbon steel forging with fabricating and other manufacturing solutions to discover how affordable and reliable this process is. Minimal waste and energy-efficient equipment add to the low costs of single- or bulk-orders of forgings.

Carbon Steel Forging Process

The closed impression die forging process creates carbon steel forgings from two or more dies. These dies are pressed together with a hammer, hydraulic or mechanical presses with capacities between 20,000 and 50,000 tons.

The process starts with a piece of raw stock ranging from a few ounces to over 25 tons in weight. The result is a three-dimensional product capable of strict tolerances. Review the steps in greater detail to see how closed impression die forging compares with other manufacturing options for your industry.

While the forgings created are personalized for your business, we follow the same reliable forging process. The process goes from raw material to shipped product in six basic steps:

  1. Material procurement
  2. Die creation and testing
  3. The forging process
  4. Cleaning the product and applying a heat treatment
  5. Coining and piercing, as necessary
  6. Full inspection and shipping to your facility

Procuring raw material requires an understanding of the basic features of various alloys and carbon content. Our team at Trenton Forging works with you to discuss the pros and cons of materials to find the optimal alloy for your forgings.

Custom dies allow for complex shapes, including flanges, ribs and pockets. Every set of dies we create undergoes testing before being used to create forgings.

The process uses our air-lift, gravity-drop hammer for effective force to shape a steel billet. The amount of pressure depends on the size of billet and alloy chosen.

After forging, the product must be cooled and cleaned. Some are then heat-treated to alter the surface characteristics. Coining and piercing help further craft your high-quality forgings.

We inspect every forging before it leaves our facility. High tolerance levels help avoid dealing with manufacturing defects in your facility. Whether you order a single prototype or a bulk order, we handle shipping carbon steel forgings to your facility for installation or sale to your customers.

Custom Forgings

Custom carbon steel forgings are one of the industry-leading forging services our american forging company has offered for over 50 years. Choose custom forgings for cost-effective and durable alternatives to custom castings.

We start any custom option by discussing your product requirements. Once we arrive at an alloy choice, we create custom dies to match your finished product designs. The intense pressure and heat applied during the forging process give you a durable mechanical part or tool. Forgings can be weather resistant or designed to handle extreme working conditions with long-lasting performance.

Create a product weighing up to 15 pounds and measuring 24 inches in length or less. A 50,000-ton mechanical press applies extreme pressure to create a custom product. Here are some common items that can be manufactured efficiently through closed-die forging:

  • Flanges
  • Fittings
  • Blocks
  • Traditional and stepped shafts
  • Cylinders and sleeves
  • Discs and hubs

We commonly produce components for the mining, trucking, military, agricultural and construction industries. These forgings are only a few examples of the custom parts you can receive from a closed-die forging process at Trenton Forging. Discuss the tolerances, surface features and other finished product specifications with our team to start the carbon steel forging process.