Heavy-duty industrial, automotive, oil and gas, chemical, and other critical applications call for forged pipes and tubes. Made from thick, durable, solid metal, forgings are extra strong for use in the most challenging operating conditions.
Ferralloy, Inc. specializes in precision metal forgings for a range of industrial applications. Learn more about forging processes for pipes and tubes and how Ferralloy supports the industries that use them.
About Forging for Metal Pipe & Tubes
Forging is a metal forming process in which a solid metal billet is heated and shaped with force, either by hammering it or pressing it between dies. Common metals used in forging include:
- Carbon steel
- Stainless steel
- Titanium
- Inconel
- Haynes
- Hastelloy
Benefits of Quality Tube Forgings
Forged products are more resistant to cracks, fatigue, impact damage, and stress. And because forged items are made from solid pieces of metal, the risk of voids, weak joins, or improperly machined features is eliminated. Additional benefits of forging for pipe and tube applications include:
1. Better Mechanical Properties
The intense pressure from hammers or dies compresses the metal and forces it into the desired shape under tremendous pressure. This doesn’t just shape the metal form—it reshapes the grain structure to align with the shape of the piece, which increases the metal’s toughness and strength.
2. Better Surface Quality
Forging minimizes surface-level flaws and potential defects in the metal. It reduces porosity and roughness for smooth, clean surfaces.
3. More Customizability
Forging with custom dies can produce highly precise and intricate shapes in many different sizes and materials. Ferralloy has the expertise and equipment to meet your requirements for nearly any forged application.
4. Resistance to Heat Damage and Corrosion
Alloys like stainless steel, titanium, and others can be forged for use in applications that require corrosion resistance. While choosing naturally heat-resistant metals results in a more heat-tolerant end product, the grain alignment created by the forging process can further enhance heat resistance properties of the material.
5. Less Material Waste
A primary measurement for forgings is the volume of the material in each finished piece. As a result, it is possible to use the exact amount of metal needed without scrap or waste. This helps make forging a cost-effective manufacturing process.
Types of Tube Forgings Available
Ferralloy offers three different processes for forged pipes and tubes: open-die, closed-die, and seamless rolled rings.
Open-Die Forgings
In open-die forging, open dies or hammers, compress the metal into shape without fully enclosing around the metal. Manufacturers use this for custom and over-sized designs where closed-die forging isn’t a cost-effective option. It allows forgers to create unique shapes and components while harnessing the strength-building benefits of forging.
Closed-Die Forgings
Closed-die forging process, also known as ‘compression-die forging’, fully encloses metal in pre-shaped dies. The dies compress the metal, forcing it into the right shape and grain alignment from all angles. Manufacturers can use this process to consistently forget small and medium-sized components, and it offers excellent surface equality and adherence to design details.
Seamless Rolled Rings
Rolled ring forging processes work best to create rings for flanges, bearings, and gear rings. Forgers pierce and roll the metal to create seamless circular rings that are strong, won’t deform over time, and don’t have a seam that could compromise its longevity.
Common Applications for Forged Metal Pipe & Tubes
Forged pipes and tubes are useful for applications that involve high pressures, temperatures, or volumes of fluids. Because they are made from contiguous sections of metal with thicker walls than can be achieved with sheet metal or through standard extrusion. Forged pipes and tubes are extremely tough. Tube ends can even be designed with built-in flanges or other features that add strength and stability without the need for joints or welds, which also adds durability. Ferralloy serves multiple industries with custom built forgings:
- Aerospace: MRO Tooling, Alloy Discs and Stackers for heat-treating operations, ground-based component parts and forged bars, & plates that require extreme heat resistance.
- Oil and gas: Drilling equipment, pipelines, and components that must resist corrosion and degradation from chemical exposure.
- Automotive: Steering and drive components. Forgings used in suspension systems and specialized trailer & hitch component parts.
- Power generation: Power plant components such as turbines and parts in heat exchangers.
We provide high-quality metal forged tubes and piping for any application that requires a high degree of strength and resistance to environmental extremes.
Quality Forged Metal Pipe & Tube by Ferralloy, Inc.
Since 1984, Ferralloy, Inc. has served customers around the world with high-quality metal forging, machining, and casting capabilities and engineering support. Our company is ISO 9001 certified, and we work with many different materials, including carbon and stainless steel, nickel alloys, titanium, and superalloys to meet customer requirements.
Contact us today to discuss your next project or to request a quote.