FORGE WELDING

FORGE WELDING
Forge welding is a solid-state welding
process that joins two pieces of metal by
heating them to a high temperature and
then hammering them together.
 PRINCIPLES
STEP 1: Metals are heated to the
plastic condition (above 1000 degree
Celsius) in a furnace.

STEP 2: Heated metals are

brought to the anvil from heat source
and superimposed them.
 Schematic representation of FORGE
welding using Hammer
CLASSIFICATION
# HAMMER WELDING
Hammering is done by heating the metal to the
proper temperature, coating with flux, overlapping
the weld surfaces, and then striking the joint
repeatedly with hammer.
ROLL WELDING
Here the heated metals are overlapped and passed
through rollers.
DIE WELDING
Here the pieces of metal are heated and then forced
into a die.
 Process parameters

• Forge-welding temperature
• Amount of deformation
• Forging speed
 TEMPERATURE
*Typically 50 to 90 percent of the melting
temperature.
*Soft low carbon steel = 1250 to 1300
degree Celsius
*High carbon and alloy steel = 1100 to
1140 degree Celsius
*Wrought iron = little below 1290 degree
Celsius
TOOLS NEEDED
# Anvil


# Standard cross peen
hammer
# Flux (Borax / Silica sand)
FORGEABLE METALS
# Aluminium alloys
# Magnesium alloys
# Copper alloys
# Carbon and low alloy steels
# Martensitic stainless steel
# Austenitic stainless steel
# Nickel alloys
# Titanium alloys
# Tungsten
alloys
 COMMON HAND TOOLS
# Hammers
# Black-smith’s gauge
# Hot chisel
# Brass
 ADVANTAGES
# Good quality welds obtained
# Parts of intricate shape welded
# No filler material required
# Required less matching after welding
# Welded joints have low initial cost
# Welded joints easily repaired
# Noiseless process
# High strength welded joints
 DISADVANTAGES
# Low carbon steel is welded
# High level of the operator skill is required
# Slow welding process
# Weld is contaminated by the coke used in
heating furnace
# Welded joints can not used for collision and
vibration
# Can not be assembled and reassembled
 APPLICATION
# Aerospace industry
# Production of crank shaft
# Shipbuilding, cycle industries
# Production of pattern-welded blades
# Manufacture of shotgun barrels
# Small tools like railroad equipments,
automobile and trucks, agricultural
machinery