Application of New Metal Forging Technologies in Critical Manufacturing Sectors

In roaring factory workshops, glowing steel billets undergo precision shaping, while silver aluminum ingots are forged into complex forms. As a time-honored metalworking technique, forging has reinvented itself to underpin modern industrial systems and is now widely applied in critical sectors such as automotive, aerospace, and energy equipment.

The diversity of forging processes provides tailored solutions for industrial applications. In heavy machinery, open-die forging produces 10,000-ton hydropower turbine shafts weighing over 200 tons each. For precision manufacturing, warm forging achieves micron-level gear tooth accuracy in automotive transmissions, reducing gear meshing errors to 1/10th of a human hair’s width, significantly lowering noise in new energy vehicle drivetrains.

Material innovations continue to expand forging boundaries. Breakthroughs in cold forging of titanium alloy aerospace fasteners reduce aircraft weight by 300 kg per plane, while micro-forging of magnesium alloy smartphone frames maintains strength while slimming consumer electronics.

Modern forging technologies now evolve along two dimensions: temperature and forming methods.
By temperature:
1、Hot forging (>800°C), dominating 75% of the market, produces heavy-duty truck hubs and construction machinery arms.
2、Warm forging (300–800°C), holding 18% share, excels in precision automotive transmission gears.
3、Cold forging (room temperature), growing at 5% annually, captures high-end fastener markets.

By forming method: Seven categories include open-die, closed-die, and ring rolling. Closed-die forging, with near-net-shape advantages, covers 60% of automotive parts, while open-die remains irreplaceable for 10,000-ton turbine shafts.

To address traditional forging’s high energy consumption and material waste, three innovations are reshaping the industry:
1、Split-flow forging boosts gear precision efficiency by 40% while cutting material loss by 15%.
2、Liquid die forging enables single-step aluminum wheel production, slashing costs by 30%.
3、Smart forging lines, adopted by 45% of industry leaders, enable 24/7 unmanned production.

Traditional workshops are undergoing digital transformation. Intelligent forging lines leverage 5G and industrial IoT for end-to-end data integration. Green initiatives also shine: waste heat recovery systems and hydrogen-powered furnaces have significantly improved environmental metrics like exhaust reuse and CO₂ emissions.

In new energy vehicles, forged motor shafts and gear rings directly impact range and safety. Aerospace relies on forging breakthroughs—a 300MN hydraulic press for aircraft landing gears generates force equivalent to three aircraft carriers’ weight.

Energy sector data shows each 5MW wind turbine requires 20 tons of forged components (e.g., main shafts, yaw rings). These forged parts withstand extreme loads comparable to Category 12 typhoons.

Industry experts predict two 2025 trends: micro-forging will overcome millimeter-level precision forming bottlenecks, while green forging will cut energy use by 25% through heat recycling. Aligned with sustainable manufacturing strategies, forging is transitioning toward high-tech precision, continuing to drive high-quality industrial advancement.Energy sector data shows each 5MW wind turbine requires 20 tons of forged components (e.g., main shafts, yaw rings). These forged parts withstand extreme loads comparable to Category 12 typhoons.

Industry experts predict two 2025 trends: micro-forging will overcome millimeter-level precision forming bottlenecks, while green forging will cut energy use by 25% through heat recycling. Aligned with sustainable manufacturing strategies, forging is transitioning toward high-tech precision, continuing to drive high-quality industrial advancement.