Aerospace Forgings and Their Role in Reducing Weight of Aircraft Parts

When it comes to aerospace engineering and aircraft design, lightweight and durable components are always the most desirable option for their ability to drive down fuel costs, increase performance, and maintain integrity under the various stressors of operation. One effective method of achieving this balance of strength and weight is through the use of aerospace forging processes for manufacturing and assembling various parts. This blog will serve to explore the fundamentals of popular forging techniques and their prevalence in the aerospace industry, uncovering the significant role they play in reducing the weight of aircraft parts without compromising durability.

In general, the process of forging involves deforming a metal into a desired shape by applying localized compressive forces. Depending on the type of equipment being used and the intended characteristics of the final assembly, such processes may be conducted with temperatures ranging from cold to hot. Forging is particularly valued for its ability to produce components with superior mechanical properties, as the alignment of a metal’s grain structure during such processes enhances toughness and fatigue resistance.

For aerospace manufacturing in particular, there are a few popular types of forging processes that are used to create components with specific characteristics that enable them to meet stringent performance requirements. Open-die forging is one of the most traditional methods, involving the deformation of metal between multiple dies that do not completely enclose the material. This process allows for considerable flexibility in the shapes and sizes of parts, making it suitable for custom or large-scale applications where precision is less critical. For example, various structural components and engine mounts are produced following the method of open-die forging.

Closed-die forging, also known as impression-die forging, is a similar process to open-die forging that simply differs in the fact that the die shapes a metal while completely enclosing it. Providing the benefit of high dimensional accuracy and repeatability, this method is more ideal for producing complex and intricate component designs. For the aerospace industry, closed-die forging is often relied on during the production of turbine blades, connecting rods, gears, and other similar parts, ensuring tight tolerances and superior performance under stress.

Another specialized technique used in aerospace sectors is ring forging, which is specifically employed to create circular components like bearings, bushings, and flanges. This process offers the advantage of providing uniform strength and dimensional stability, which are both beneficial qualities for items that are subjected to rotational forces and high stress. As a final example we will discuss, an advanced forging method known as hot isostatic pressing (HIP) utilizes high-pressure gas environments during the process to eliminate internal voids and enhance the density and integrity of forged parts.

The properties of aerospace forgings contribute significantly to the goal of reducing aircraft weight, all while maintaining the necessary durability to perform reliably during flight operations. For example, forged components typically exhibit higher strength-to-weight ratios when compared to equivalent cast or machined parts, allowing for lighter structures to be created without sacrificing any performance or safety qualities. Providing the means of achieving superior mechanical properties like high tensile strength and resistance to fatigue, forging also reduces the likelihood of mechanical failures and extends the service life of many components. This has a dual benefit of enhancing the safety and reliability of aircraft while lowering maintenance costs and downtime, offering significant economic advantages to airlines and operators.

Inspecting and repairing forged components is a critical aspect of maintaining their integrity. While visual inspections should be carried out on a regular basis, utilizing non-destructive testing methods like ultrasonic testing and X-ray inspections is highly recommended to more accurately guarantee that forged parts are free from any defects or damage that would otherwise be undetectable to the naked eye. Any signs of wear or deformation should always be promptly addressed, where reforging or reinforcing can often be conducted without the need for a complete replacement.

For those seeking high-quality forging solutions and other aerospace components for operations, Click Aerospace offers a comprehensive range of options that are tailored to meet the diverse needs of the industry. Our inventory exceeds 2 billion listings with additions regularly made, everything featured across the website being readily available for purchase at any time with competitive pricing and on-time delivery guarantees. Simply fill out and submit a Request for Quote (RFQ) form through our website with information concerning your requirements, and a member of our staff will respond shortly after a review with customized procurement options for your consideration. You are also welcome to call or email directly, so do not hesitate to reach out to learn more about our services and solutions.