Forging quality control employee

Forging Quality Control evolves around ensuring forged components meet performance standards by addressing material inconsistencies, dimensional inaccuracies, and surface defects.

Contents

forged part

Introduction

forging operation

Robust quality control measures must be in place throughout the manufacturing process to meet stringent performance standards. Quality control ensures that forged parts meet specified tolerances, comply with industry standards, and function reliably in their intended applications.

Forging involves deforming metal under high pressure to create strong and durable components. While this process inherently improves mechanical properties such as strength and resistance to fatigue, it also introduces risks such as material inconsistencies, dimensional inaccuracies, or surface defects.

Challenges in Forged Part Quality Control

Variability in composition, grain structure, and purity:

Impact :

  • Poor mechanical properties (e.g., reduced toughness/strength).
  • Inclusions/impurities weaken parts.
  • Unpredictable deformation during forging.

Inherent flaws such as porosity, cracks, or inclusions in raw materials.

Impact :

  • Compromises the integrity and strength of the final product.

Extreme temperatures introduce risks and overheating/underheating affects grain size.

Impact :

  • Poor mechanical properties due to grain size issues.
  • Cracks or distortions.

Repeated high-pressure use causes die wear and deformation.

Impact :

  • Dimensional inaccuracies.
  • Surface defects like scoring.
  • Reduced tool life and higher downtime.

Tight control of force, temperature, and strain rate is essential.

Impact :

  • Improper grain flow patterns.
  • Unfilled sections in parts.
  • Internal stresses lead to fatigue failure.

Tight control of force, temperature, and strain rate is essential.

Impact :

  • Improper grain flow patterns.
  • Unfilled sections in parts.
  • Internal stresses lead to fatigue failure.

Ensuring tight tolerances in industries like aerospace.

Impact :

  • Manual measurements risk inaccuracies.
  • Automated systems (e.g., CMMs) require extensive programming.

Uneven heating or cooling during post-forging treatments like quenching and tempering.

Impact :

  • Residual stresses or warping.
  • Variability in cooling rates affects hardness and strength.

Quality Control Steps

Raw Material Inspection

Quality begins with the selection and inspection of raw materials. Forging relies heavily on high-grade metals such as steel, aluminium, or titanium, depending on the application. Raw material inspection includes:

  • Inclusion Testing: Detects impurities that may weaken the forged part.

  • Microstructural Examination: Verifies grain size and distribution, critical for mechanical performance.

  • Chemical Composition Analysis: Ensures the material meets specified alloy requirements.

steel billet

Pre-Forge Process Checks

Before forging, the material undergoes processes such as cutting, heating, and conditioning. Quality control measures during this stage include:

 

  • Dimensional Checks of Billets or Bars: Ensures consistent input sizes for uniform forging outcomes.

  • Heating Uniformity: Controlled heating is critical to prevent thermal stresses or grain distortion.

  • Surface Cleanliness: Contaminants such as oxides or grease can lead to surface defects in the finished product.

heating steel billets for forging1

Forging Process Monitoring

During forging, several parameters must be controlled to ensure the desired properties in the final part:

 

  • Die Condition Monitoring: Worn or damaged dies can result in dimensional inaccuracies or surface flaws.

  • Temperature Control: Maintaining optimal forging temperatures prevents material cracking or incomplete deformation.

  • Force Calibration: Presses and hammers must deliver precise forces for consistent results.

casting temperature control

Post-Forging Heat Treatment

Heat treatment enhances the mechanical properties of forged parts, such as hardness, toughness, and fatigue resistance. Quality control in this stage focuses on:

  • Temperature and Time Monitoring: Adherence to heat treatment cycles ensures uniform material properties.

  • Quenching Medium Analysis: Ensures the cooling rate aligns with material specifications.

  • Hardness Testing: Verifies the effectiveness of the heat treatment.

steel billet
forged part assortment

Testing Methods for Forged Parts

1- Non-Destructive Testing (NDT)

NDT techniques are critical for detecting internal and surface defects without damaging the part:

  • Ultrasonic Testing (UT): Detects internal cracks, voids, and inclusions.
  • Magnetic Particle Inspection (MPI): Identifies surface and near-surface defects in ferromagnetic materials.
  • Dye Penetrant Testing (DPT): Highlights surface cracks and porosity in non-ferromagnetic materials.
  • Radiographic Testing (RT): Uses X-rays or gamma rays to identify internal defects.
forging ndt
forging cmm

2. Dimensional and Geometric Accuracy

Forged parts must adhere to strict dimensional tolerances to ensure compatibility with assemblies. Measurement tools include:

  • Coordinate Measuring Machines (CMM): Provides precise 3D measurements of complex geometries.
  • Optical Scanning Systems: Captures detailed surface profiles.
  • Calipers and Micrometers: Used for simpler dimensional checks.

3. Mechanical Property Testing

Testing mechanical properties ensures the part can withstand operational stresses. Common methods include:

  • Tensile Testing: Measures ultimate tensile strength, yield strength, and elongation.
  • Impact Testing (Charpy or Izod): Assesses toughness under sudden loading.
  • Fatigue Testing: Evaluates the part’s ability to resist cyclic stresses.
  • Hardness Testing: Verifies surface and core hardness levels.
Hardness Testing
Quality-control-template

4. Traceability and Documentation

A comprehensive quality control system includes traceability and documentation of every step:

  • Material Certifications: Ensures compliance with industry standards such as ASTM or ISO.
  • Inspection Reports: Records all dimensional and NDT results.
  • Heat Treatment Logs: Tracks temperature and quenching conditions.
  • Serial Number Tracking: Enables traceability in case of failures or recalls.

How can we help you ?

Novelty Structures stands out as a reliable supplier of high-quality Forging services with complementary Post-Forging Operations tailored to demanding industrial needs.

Contact our team to further discuss your needs.

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