High tolerance open and closed die forging

Best-in-class forging capabilities, extensive global operations.

 

Alcoa capabilities include:

 

  • 24,000 Square Inches of Plan View
  • Up to 10,000 lbs. Forged Aluminum Block
  • Alloy Design
  • Aluminum Research

 

Increase efficiency and product performance

 

Alcoa’s leading edge forging facilities and technology can help you dramatically reduce manufacturing costs, increase capacity and throughput, and improve product performance. As a proven solutions provider, Alcoa combines design and manufacturing expertise with advanced metallurgical science to deliver what the customer, and the industry demands.

 

Our global network of forging facilities serves as the world’s most extensive line of forging assets. This is why Alcoa Oil and Gas is positioned to deliver what the industry wants and demands for future success and growth.

 

From collaborative design to concurrent engineering, we work closely with each customer to help optimize structural solutions and offer new options and opportunities in forged metallics. Our team of seasoned technical experts, along with our unmatched metallics database, combine to ensure innovative, customer-driven solutions in the most responsive manner possible.

 

Open and closed die forging of large parts

Capabilities

 

We manufacture closed and open die forgings in a wide range of metals, including steel, aluminum, titanium, and nickel-based alloys. Our capabilities range up to 24,000 square inches of plan view on parts weighing as much as 10,000 lbs. We’re able to deliver large monolithic, near-net shape components – this reduces the need for welds, reduces the number of stress points, and overall, reduces costly machining and assembly processes.

 

Alcoa is equipped with a full range of computer controlled forging presses from 3,000 tons to the world’s largest 75,000 metric ton press, both open-die and closed-die presses. Our forging design and manufacturing capability reduces product launch time and allows our customers to take advantage of die forgings on the very first production part or test article. Concurrent engineering capabilities aid in the design of monolithic forgings, replacing build-up assemblies and reducing part counts and cost. Alcoa also offers forged blocks, including contours, in aluminum up to 30,000 lbs.

 

The Alcoa Signature Cold Work Process™ minimizes residual stress in our forged products, allowing better machining with little distortion.

 

Technical resources and research

 

These advanced capabilities are supported by Alcoa’s extensive aluminum research capability; designing new alloys to meet the needs of weight reduction, cost reduction or improved service life. We have broad experience in a wide range of metals, including steel, aluminum, titanium, and nickel-based alloys.

 

Utilizing state-of-the-art design tools to enhance simulated technology, Alcoa offers residual stress analyses and program launch results. These tools include:

 

Commercial CAE Codes Used
Deform 2d & 3d, LS-Dyna, Ansys, Aries, HyperMesh,

Abacus (lab)
Alcoa Proprietary Codes Used
Blocky (domain specific design & integrated verification tool)

Commercial CAD Codes Used
Catia V4 & V5, Cadds5, Patran, Studio, Paraform, Pro-E, Unigraphics, AutoCad
Commercial CAM Codes Used
WorkNC, CVNC, Catia V5 Turning, Vericut