Like steel forgings and aluminum forgings, copper forgings in CT Forge are operated under hot forging condition as well. Below are the main steps of hot forging process of cooper alloys in our company:

Rod Cutting
Before forging, we will first order cooper bars with the right specification (such as Φ30mm) from the material factory. When they are in stock, to insure filling the die cavity during forging, billets will be cut to a certain length according to the dimensions of final cooper forgings. 

Heating
Since the billet will be forged under hot condition, the billets are then heated to a certain forging temperature. To insure a quality part, the forger must carefully control the billet temperature, as too cold the billet will not fill the die cavity completely whereas too hot it will result in a porous surface.

Forging
The dies are heated to insure proper metal flow, and the heated billet is placed in the lower half of the die cavity. With a downward stroke of the forging ram, the upper die is forced against the billet to form the desired shape. Since copper and copper alloys are readily forged, most commercial forgings are produced with a single closing of the press, no re-strike or reheating being required. This permits the use of single cavity dies rather than the more expensive progressive dies required by hard-to-forge materials, and reduces labor costs, die costs, and heating costs. 

Forging rates vary between 100 and 1,200 pieces per hour with the majority of forgings being forged at 200 to 600 piece rates. Where quantities are large and the design is simple, considerable savings result from the use of multiple cavity dies, with more than one part being produced at a time.

It is during this process that the dense grain structure of the hot wrought extruded brass rod is further hot worked to assure a dense uniform product with excellent physical and mechanical properties. These superior properties frequently permit the use of forged parts which are lighter than those produced by other processes.

Trimming 
To insure complete filling of the die cavity, the weight of the forged copper part slightly exceeds that required by the finished forging. To allow for this excess metal, a gutter or relief area is provided in the die surface surrounding the die cavity. During forging, the excess metal is extruded into the gutter as overflow or flash which is removed later in a trimming operation. Good forging die design keeps the amount of flash to a minimum for minimum scrap. Since the flash thickness varies with the ram pressure on the die, the amount of excess metal, the billet temperature when forged, and the die temperature, the flash thickness dimension customarily has twice the tolerance allowed for other dimensions of the part. Where tighter outside dimensions are specified, a close trimming operation known as shaving can be substituted.

Dip Finishing
During the forging process surface oxides form and the parts are coated with lubricants picked up from the dies. Both these surface layers are dissolved by dipping the parts in a series of special solutions. After the forgings are clean, they are generally dipped in a passivating bath to insure a clean surface for subsequent handling.

Due to the stringent requirements of the Environmental Protection Agency, some forging suppliers have substituted a steel ball tumbling operation for dipping to clean cooper forgings.

• Copper forging provides higher production rates over copper casting.
• There is greater material strength in forged cooper parts due to the total absence of porosity. Forging improves the mechanical properties, because of the closeness of the grain flow.
• The absence of porosity and inclusions also significantly reduce scrap.
• The ductility of brass at forging temperatures allows for the easier formation of complex components; further the use of vertical and horizontal sub-presses enhances the application of multiple cores.
• The superior surface finish produced from copper forging over casting, means that grinding or sanding is not required before polishing; therefore it is easier to apply wide range of finishes.
• The closer tolerances and net shape accuracy provided by cooper forging reduce machining operations.
• Substantial material savings are generated due to the coring process along with the reduction in flash.
• Longer machine tool life is experienced due to the absence of the inclusions seen in sand casting.
• Lower Forge tooling costs over casting tooling.
• Many copper castings can be easily converted to copper forgings

CT Forge, the largest copper drop forging manufacturer and supplier in China,  takes great pride in producing high-quality, closed-die brass and copper forged parts, specifically in the areas of automotive electrical components, aerospace, energy and defense industries. For over 30 years, our diverse customer base has trusted us to be part of their team, allowing us to help them create the often complex products they design. After thoroughly reviewing the specs in our APQP product review process, we work together with our clients to provide them with creative solutions for their unique designs.

Closed-die forging, the process most widely used by CT Forging Company, is the most cost effective forging process for high-volume production. The initial costs for the tooling and the equipment may be higher, but it can be an excellent investment long-term as the recurring costs of the parts is very low.

Some of the numerous advantages to copper, brass and bronze forging includes close tolerances, strength, leak resistance and low overall costs. Mass production of forged copper parts offers maximum savings for CT Forge clients. Conversely, smaller quantities of copper forgings can prove to be the most economical when specific design problems, such as leak integrity, close tolerances, high strength with low weight, and non-symmetrical shape, must be resolved.

Besides forging, CT Forge can also provide post machining service, which will enable us to deliver finished copper components to our customers directly. 

Contact us now for your FRQs on Copper, Brass or Bronze Forging Project!

Brass ball valve bodies are created using a forging method that involves shaping metals and alloys while they’re in their solid form. Heat and industrial-size tools deliver compressive forces to bend the metals and alloys, and dies are used to cut and shape the materials to create specific valves. Forging can be performed in most temperatures depending on the brass used. Forging ball valve bodies presents many benefits for industrial companies. For example, companies don’t have to worry about wasted materials. Since forged ball valve bodies are shaped into one solid piece, little effort is needed to rework the material to achieve the proper shape and size. Forged ball valve bodies have a reputation for being strong, which make them ideal for handling high-pressure and high-temperature systems. During the brass forging process, the metal’s grain structure becomes more refined. This leads to an increase in impact and overall strength. Also, forging boosts its resistance to common issues such as cracks, shrinkage, and porosity.

On top of that, brass forging can create ball valve bodies with less wall thickness. This helps to reduce the likelihood of thermal fatigue during valve operation. This also means that forged brass ball valve bodies can be heated and cooled more quickly, which allows them to adequately handle the stresses of systems that continuously cycle through start-up and phase-down processes. Would like to source a brass forging for your ball valve bodies or other valve components? Pls contact us for your RFQs?

C37700 Brass is an alloy mainly consisting of copper and zinc. This type of brass can be easily forged and are available in various shapes. Brass has high thermal conductivity. UNS C37700 forging brass alloys have good forgeability. C37700 brass forgings are produced from different specifications of brass rods.

CT Forge are acknowledged as the distinguished manufacturer, exporter and supplier of brass forgings.  In China, the alternative brass grade of C37700 is HPb59-1, this types of brass forgings are widely used in automobile, marine, construction and other allied industries for various purposes. The provided brass is manufactured by our trained professionals with the help of modern machinery using copper and zinc as per the set international standards. The offered C37700 Forging Brass is easy to fabricate and is made available with us in different sizes, thickness and finishes at market leading price.

C11000 Copper, also known as Electrolytic Tough Pitch, is 99.90% pure copper. C11000 is one of the most commonly used commercially pure coppers and is available in a variety of shapes, including plate, sheet, coil, bar, rod, wire and extruded profiles. C11000 copper has high electrical conductivity, in excess of 100% IACS, and good corrosion resistance. C11000 copper has a wide range of uses, including applications inarchitectural, industrial, electrical, automotive and construction industries. Some common products produced out of C11000 ETP copper include roofing, gutters, radiators, switches, fasteners, conductors, cookware and heat exchangers. 

In China, if forging, it is difficult to order C11000 copper bars directly from domestic material factory, so we normally use T2 material instead. Surface finish of C11000/T2 copper forgings available in CT Forge can be shot blasting, silver plating, nickel plating, ect. Besides, we can also provide value added machining service to deliver finished machined products. Contact us now if you require C11000 copper forgings or forgings in other copper alloys.

Forging is the metal processing process that puts pressure on metal billets, which will occur plastic deformation to achieve a certain mechanical properties and desired shape by the use of forging press machinery. Brass is the most common material in copper forging.

Brass Forging is usually operated under high temperature, we call this hot forging. Brass can have good plasticity both under room temperature and high temperature, but it has better mobility, which will reduce metal deformation resistance. This will not only increase the forgability of brass, but also make brass easy to flow and form.

Although brass has good plasticity at room temperature and high temperature, there is a medium temperature brittleness zone, so the forging temperature range is narrow. Temperature control is of vital importance. Taking HPb59-1 for example, the proper forging temperature should be at 680-750℃。