What Are the Materials Used for Forging?

Forging is a widely adopted manufacturing process used to shape metals under high pressure. It is known for producing strong, reliable, and defect-resistant components that are essential in high-performance industries such as automotive, aerospace, oil and gas, construction, and machinery. However, not all metals are suitable for forging.

The materials used for forging must possess the right combination of strength, ductility, thermal stability, and machinability to meet the demands of the process and the final application. This article explores the most common forging materials, their key properties, and why they are selected for different industries and environments.

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Overview of Forging Materials

Materials used in forging fall into three primary categories:

1. Ferrous Metals (containing iron)

2. Non-Ferrous Metals (not primarily iron)

3. Specialty Alloys (nickel-based, titanium, and cobalt alloys)

Each type offers unique benefits for strength, corrosion resistance, cost-effectiveness, or high-temperature performance.

Ferrous Metals Used in Forging

1. Carbon Steel

Carbon steel is one of the most common forging materials due to its versatility and cost-efficiency.

• Low Carbon Steel (up to 0.3% carbon)

  • High ductility and machinability

  • Used in automotive parts, hand tools, and fittings

• Medium Carbon Steel (0.3%–0.6% carbon)

  • Better strength and hardness

  • Common in shafts, gears, connecting rods

• High Carbon Steel (0.6%–1.0% carbon)

  • Very hard and wear-resistant

  • Used in knives, dies, and springs

Key Grades: AISI 1018, AISI 1045, AISI 1095

2. Alloy Steel

Alloy steels are enhanced with elements like chromium, molybdenum, nickel, and vanadium to improve toughness, strength, and wear resistance.

• Excellent hardenability and fatigue strength

• Can be heat-treated for specific mechanical properties

• Ideal for demanding applications

Common Uses: Crankshafts, transmission gears, structural components

Key Grades: 4140, 4340, 8620, 42CrMo4

3. Stainless Steel

Stainless steel is chosen for forging when corrosion resistance is a priority.

• High chromium content offers oxidation and corrosion resistance

• Good strength and toughness

• Suitable for food processing, marine, and medical industries

Types:

• Austenitic (e.g., 304, 316): Non-magnetic, high corrosion resistance

• Martensitic (e.g., 410, 420): Magnetic, higher hardness

• Ferritic (e.g., 430): Moderate strength and corrosion resistance

Common Forged Parts: Flanges, pump shafts, surgical instruments, fasteners

sakysteel provides a wide range of stainless steel forgings tailored to different applications.

Non-Ferrous Metals Used in Forging

1. Aluminum and Aluminum Alloys

Aluminum is widely used in forging due to its light weight, corrosion resistance, and excellent strength-to-weight ratio.

• Easy to forge and machine

• Ideal for aerospace, automotive, and transportation parts

Key Grades:

• 6061 – High strength and corrosion resistance

• 7075 – High strength, often used in aerospace

• 2024 – Excellent fatigue resistance

Typical Applications: Control arms, aircraft fittings, wheel hubs

2. Copper and Copper Alloys (Bronze and Brass)

Copper-based materials offer excellent electrical and thermal conductivity.

• Used in electrical connectors, plumbing fittings, marine components

• Forged parts resist wear and corrosion

Key Alloys:

• C110 (pure copper)

• C360 (brass)

• C95400 (aluminum bronze)

3. Magnesium Alloys

Although less common, magnesium alloys are used where lightweight materials are critical.

• High strength-to-weight ratio

• Often used in aerospace and electronics

• Requires controlled forging conditions

Limitations: More expensive and reactive during processing

Specialty Alloys Used in Forging

1. Nickel-Based Alloys

Nickel alloys are forged for their outstanding high-temperature and corrosion resistance.

• Essential in chemical processing, power generation, and aerospace

• Withstand extreme stress, heat, and chemical attack

Key Grades:

• Inconel 625, 718

• Monel 400

• Hastelloy C-22, C-276

sakysteel supplies nickel alloy forgings for severe service conditions.

2. Titanium and Titanium Alloys

Titanium offers a unique combination of strength, low density, and corrosion resistance.

• Used in aerospace, marine, and medical applications

• Expensive but ideal where performance justifies the cost

Key Grades:

• Grade 2 (commercially pure)

• Ti-6Al-4V (high strength aerospace grade)

3. Cobalt Alloys

Cobalt-based forgings are highly wear-resistant and maintain strength at high temperatures.

• Common in turbine components, engine parts, medical implants

• High cost limits usage to very specialized applications

Factors Influencing Material Selection in Forging

Choosing the right material for forging depends on several key factors:

• Mechanical strength requirements

• Corrosion and oxidation resistance

• Operating temperature

• Machinability and formability

• Fatigue and wear resistance

• Cost and availability

Engineers must balance these factors to ensure the forged component performs reliably in its end-use environment.

Common Forged Products by Material Type