Custom Aluminum Forging for the Components
You Need. When You Need Them.

Our
Resources

OUR CAPABILITES

What is Forging?

Forging is the shaping of hot metal completely within the impression or cavities of two die halves that come together to contact the work piece.

Impression-die forging, often referred to as closed-die forging, is a process where the dies are designed to manage the flow of excess material—known as flash—produced during the operation.

REQUEST QUOTE

Extrusion
vs Casting
vs Forging

Aluminum Extrusion

Process:

  • A heated aluminum billet is pushed or drawn through a die to create long profiles with a consistent cross-section.
  • Can be solid, hollow, or semi-hollow profiles.

Advantages:

  • High dimensional accuracy for long, uniform cross-sections.
    Minimal material waste.
  • Good surface finish and easier secondary processing (cutting, machining, anodizing).
  • Strong along the extrusion direction due to grain alignment.

Disadvantages:

  • Susceptible to surface oxidation, internal cracking, and surface lines.
  • Requires post-processing to remove oxidation.
  • Lower stiffness compared to forging.
  • Limited to simpler geometries due to its 2D nature.

Aluminum Casting

Process:

  • Metal is heated to a molten state and poured or injected into a mold.
  • Solidifies into the desired shape as it cools.
  • Methods: Sand casting, die casting, investment casting, permanent mold casting.

Advantages:

  • Ideal for complex geometries.
  • No size limitation (especially in sand casting).
  • Can be cost-effective depending on application.

Disadvantages:

  • Lower strength compared to forging.
  • Risk of internal porosity, surface voids, and imperfections.
  • Lower impact and pressure resistance.
  • Poor surface finish in sand casting; may require additional machining.

Aluminum Forging

Process:

  • Solid metal is compressed into shape using extreme force.
  • Closed-die forging is most commonly used at BAFE.

Advantages:

  • Produces high-strength, durable parts.
  • Excellent for complex, intricate designs with tight tolerances.
  • Superior grain structure enhances structural integrity.
  • Eliminates porosity, cavities, and voids.
  • Provides good surface finish and dimensional accuracy.

FORGING ADVANTAGES VS… CASTING

  • Higher Mech properties
  • No porosity
  • Better ductility
  • Better toughness
  • Improved fatigue performance
  • Reduced weight

FORGING ADVANTAGES VS… WELDING / FABRICATING

  • Single Piece monolithic structure
  • Tighter tolerances
  • No localized heat distortion
  • Simplified production processes
  • Better machinability
  • Cost-effective design and inspection methods

FORGING ADVANTAGES VS… MACHINING

  • Broader size range of desired material grades
  • Grain flow provides higher strength
  • More economical use of material
  • Yields lower process scrap
  • Requires fewer secondary operations

FORGING ADVANTAGES VS… POWERED METAL

  • Stronger
  • Higher integrity throughout component
  • Requires fewer secondary operations
  • Greater design flexibility
  • Less costly materials

directional strength

Directional Strength is a direct result of the forging process. In the forging process, controlled deformation results in greater metallurgical soundness and improved mechanical properties of the material.

This produces directional alignment, or “grain flow”, for important directional properties in strength, ductility, and resistance to impact and fatigue. These properties can be deliberately oriented in directions requiring maximum strength.

Grain Flow is defined as fiber-like lines appearing on the polished and etched sections of material that are caused by orientation of the constituents of the metal in the direction of working during forming. Grain flow produced by proper die design can improve the mechanical properties of forgings

GRAIN FLOW COMPARISON OF DIFFERENT PROCESSES

FORGED BAR
Directional alignment through the forging process has been deliberately oriented in a direction requiring maximum strength. This also yields ductility and resistance to impact and fatigue.

MACHINED BAR
Unidirectional grain flow has been cut when changing contour, exposing grain ends. This renders the material more liable to fatigue and more sensitive to stress corrosion cracking.

CAST BAR
No grain flow or directional strength is achieved through the
casting process.