Forging Course

Lesson 1 • Core Forging Terminology

Defines essential vocabulary used throughout the trade. Accurate terminology enables safe communication and precise instruction-following.

Lesson 2 • Industry Applications and Career Paths

Maps forging to aerospace, automotive, tooling, and energy sectors. Motivates learners by connecting skills to real employment contexts.

Lesson 3 • Metallurgical Principles for Forgers

Covers grain structure, plasticity, and how heat affects metal behavior. Links material science directly to forging outcomes.

Lesson 4 • Overview of Forging Methods

Introduces open-die, closed-die, roll, and press forging at a conceptual level. Sets the stage for deeper study in later chapters.

Lesson 1 • Material Traceability and Documentation

Establishes practices for heat number tracking, certifications, and material records. Traceability is mandatory in regulated industries.

Lesson 2 • Non-Ferrous Metals in Forging

Addresses aluminum, titanium, copper alloys, and nickel superalloys. Each material requires distinct temperature ranges and tooling strategies.

Lesson 3 • Billet Preparation and Inspection

Teaches cutting, surface conditioning, and pre-forge inspection of stock material. Proper preparation prevents defects and tool damage.

Lesson 4 • Carbon and Alloy Steel Grades

Examines low, medium, and high carbon steels plus common alloy additions. Connects grade selection to strength, toughness, and forgeability.

Lesson 1 • Gravity and Power Drop Hammers

Explains board, air, and steam drop hammers including energy ratings and stroke control. Foundational equipment knowledge for open-die and impression work.

Lesson 2 • Auxiliary Tooling and Fixtures

Covers swages, fullers, flatters, mandrels, and holding fixtures. Auxiliary tools extend the range of shapes achievable on standard equipment.

Lesson 3 • Mechanical and Hydraulic Presses

Covers eccentric, knuckle-joint, and hydraulic press designs and their force-stroke profiles. Press selection directly affects dimensional accuracy.

Lesson 4 • Tooling Inspection and Replacement

Establishes criteria for die wear, cracking, and dimensional drift requiring action. Timely tooling replacement prevents scrap and equipment damage.

Lesson 1 • Forging Temperature Ranges by Metal

Defines optimal forging windows for steel, aluminum, titanium, and superalloys. Working outside these ranges causes cracking or inadequate deformation.

Lesson 2 • Pyrometry and Temperature Measurement

Covers contact thermocouples, optical pyrometers, and infrared sensors for forging. Accurate measurement is the basis for process repeatability.

Lesson 3 • Furnace Types and Selection

Compares gas, electric, induction, and salt-bath furnaces for forging applications. Selection affects throughput, uniformity, and surface quality.

Lesson 4 • Soaking Time and Heat Uniformity

Teaches soak time calculation based on section thickness and alloy type. Uniform temperature throughout the billet ensures consistent deformation.

Lesson 1 • Bending and Straightening

Addresses hot bending over mandrels and swage blocks plus springback correction. Accurate bending requires understanding elastic recovery in hot metal.

Lesson 2 • Producing Basic Open-Die Shapes

Integrates upsetting, drawing, and bending into complete shape sequences. Students plan and execute multi-step operations to produce specified forms.

Lesson 3 • Drawing Out and Elongation

Covers reducing cross-section while increasing length using flat and V-dies. Drawing is fundamental to producing shafts, bars, and tapered forms.

Lesson 4 • Upsetting and Heading Operations

Teaches axial compression to increase cross-section and reduce height. Upsetting is the starting operation for flanges, discs, and preforms.

Lesson 1 • Lubrication in Closed-Die Forging

Addresses graphite, glass, and synthetic lubricant selection and application methods. Lubrication reduces friction, controls flash, and extends die life.

Lesson 2 • Die Setup and Alignment

Teaches mounting, shimming, and aligning upper and lower dies on hammers and presses. Misalignment causes mismatch defects and accelerated die wear.

Lesson 3 • Closed-Die Process Fundamentals

Explains metal flow within enclosed impressions, flash formation, and cavity fill. Understanding flow patterns is prerequisite to die setup and troubleshooting.

Lesson 4 • Flash Trimming and Part Removal

Covers hot and cold trimming dies, trim press setup, and safe part extraction. Trimming completes the closed-die cycle and prepares parts for inspection.

Lesson 1 • Root-Cause Analysis of Defects

Applies fishbone diagrams and 5-Why analysis to forging defect scenarios. Systematic analysis prevents recurrence rather than just correcting symptoms.

Lesson 2 • Non-Destructive Testing Methods

Covers magnetic particle, dye penetrant, ultrasonic, and radiographic inspection. Each method targets specific defect types and depth ranges.

Lesson 3 • Dimensional Inspection Techniques

Teaches use of calipers, gauges, CMM, and optical comparators for forging measurement. Dimensional conformance is verified before heat treatment and machining.

Lesson 4 • Statistical Process Control in Forging

Introduces control charts, Cpk, and sampling plans for forging process monitoring. SPC shifts quality assurance from inspection to prevention.

Lesson 1 • Straightening and Sizing Operations

Covers press straightening, coining, and sizing to correct distortion after heat treatment. These operations bring forgings within final dimensional tolerances.

Lesson 2 • Hardening and Tempering Forgings

Teaches quench-and-temper cycles for achieving target hardness and toughness. Heat treatment parameters are alloy-specific and must be precisely controlled.

Lesson 3 • Final Inspection and Certification

Integrates dimensional, surface, and mechanical test results into a forging certification package. Certification documents compliance with customer and regulatory requirements.

Lesson 4 • Surface Cleaning and Descaling

Addresses shot blasting, acid pickling, and tumbling for scale and oxide removal. Clean surfaces are required for accurate inspection and coating adhesion.