A few pounds up to more than 150 tons of forged materials can be produced using open die forging. It is known as open die forging because the metal is not laterally constrained by impression dies when forging. It gradually shapes the initial stock into the required shape, typically between flat-faced dies.  

In reality, there are numerous process modifications in open die forging, which enables the production of a wide variety of shapes and sizes. The sheer size capability of open die forging makes it the obvious process choice over non-forging alternatives when design constraints demand the best structural integrity for a large metal component.  

worker checks open die forging process

Open Die Forging and Steel  

Material Used in Open Die Forging  

Open-die forgings are only constrained at the upper end of the size range by the size of the beginning stock or the biggest ingot that can be cast. All forgeable ferrous and non-ferrous alloys, including some unusual materials like age-hardening superalloys and corrosion-resistant refractory alloys, can be forged using an open die. However, the most commonly used material is steel.  


Hammering produces approximate dimensions, therefore, after the open die forging process, further rough precision machining is needed. Large pieces weighing several tons are better suited for the open die metal forge components. In general, the forgings that fall under this category are long shafts, rollers, and cylinders. They are mostly used in the aviation and rail industries.  

Options for Custom Open Die Forging Metal  

Most services of a custom open die forging maker are excellent for prototypes and small quantities, and the quality-controlled heat treatments and in-house machining ensure the highest quality of your finished product. Ferralloy Inc. provides specialized open-die forgings for many different metals, such as:  

  • Different metal alloys  
  • Carbon steel  
  • Stainless steel  

Additionally, most open die forgings can be produced to AISI, ASTM, AMS, API, SAE, ASME, AWS, JIS, and GB specifications for metal alloys in a variety of custom forged shapes and heat-treated conditions to attain critical physical properties, such as elongation, yield, tensile, and reduction of area for the desired end-use as specified by the purchaser.  

employee carefully checks open die forging product

Get in Touch with Ferralloy Inc. If You Need Open Die Forging  

Ferralloy has the expertise, resources, and capacity to satisfy, if not surpass, all of your specific open-die forging requirements. For additional details or to get a quote, get in touch with our professionals right away.