1. Can you give me an indicative idea of the price of a forging?
   A lot depends on the complexity of the part. As a rough guide, for most forgings, the selling price is approx. twice the cost of the raw material. Other factors which need to be considered include the quantity of forgings required, and type of material from which the forgings are to be made. Also additional processing costs such as heat treatment, need to be considered. Accurate estimates and quotations can be supplied by most forging companies within 2-3 days.
    
2. Why should I buy a forging?
   Forgings are produced from wrought bar which is free from inherent defects, such as porosity associated with castings. Because of the way forgings are produced, the flow lines of the original bar stock are worked in a manner to develop maximum mechanical properties in all directions of the forging. Due to the superior properties of forgings they may be designed to be of lighter weight than products made by other processes. To sum it up, forgings are more reliable, they are internally sound, and when properly designed have superior mechanical properties, particularly under impact and fatigue loading conditions.
    
3. What standard tolerances are applied to forgings?
   Closed die forgings are supplied in accordance with the standards laid down by the United States Drop Forging Association. These standards cover thickness, match, radii, straightness, draft angles, surface condition and die wear. Upset forgings are usually produced in accordance with British Standard No 4114. Close dimensional tolerances are also specified where forgings are required to be produced to closer limits. Forgings may be cold coined to produce even closer tolerances on specific faces. The whole question of tolerance needs to be discussed with the forging supplier, as very often a satisfactory arrangement can be negotiated on specific tolerance requirements. Forgings produced in non-ferrous metals and by warm or cold forging methods will be more tightly toleranced than those produced by hot forging of steel.
    
4. Can I have closer tolerances?
   Yes, this question has been mostly answered in reply to question 3, and needs to be discussed with your forging supplier. However, due to extra processing arrangements involved with closer to size forgings, and a reduction in expected die life of some items these type forgings may involve some additional cost. Again this is a matter for negotiation.
    
5. How do you inspect for dimensions?
   The procedure is laid down in the quality assurance manual. Samples for dimensional inspection are taken at specified times during production. Additionally, an audit check is taken on all products prior to dispatch. Tooling is checked at the completion of the forging run and refurbished as necessary to ensure consistency of future production.
    
6. Can you supply me with a dimensional test certificate?
   Yes, as all dimensions are recorded during production and audit, it is simply a matter of extracting the relevant information, and recording it on a certificate. All certificates are checked, and signed by the quality assurance manager or his nominee.
    
7. Do you carry out first and last off sample checks?
   Yes, this part of our quality assurance procedure, and is a necessary part of the operation to ensure that tooling is properly maintained.
    
8. When are tooling cavities recut?
   This question has been partly answered in reply 7 above. Cavities are recut when the tooling has worn and is unable to produce the required dimensional accuracy.
    
9. Do you have an approved quality system?
   To be approved, Australian forges must meet the requirements of Australian Standard 9000 series. Conformity is checked periodically by approved assessors, and in some instances a customer may carry out a quality audit to ensure that the system is operating satisfactorily.
    
10. May I have a copy of your quality control manual?
    Most prospective customers require a copy of the forge quality control manual. All copies of these manuals are numbered, and recipients recorded, so that updates may be issued as necessary.
     
11. Please explain how tooling charges apply.
    The system of applying tooling charges will vary from forge to forge. Generally, a first only tooling charge will apply, unless of course, there is a customer initiated design change. The piece price per forging includes a factor, which covers the cost of die refurbishment, and replacement when necessary. In some instances, a forging company will quote a part tooling charge. In this situation, the die servicing charge included in the piece price is increased, so that the complete tooling bill is paid in an agreed period.
     
12. Are there any on going tooling charges?
    As explained above, the forging price includes a factor to cover all subsequent tool repairs, and replacement. The only charge applicable would be to cover a customer initiated design change. This would depend on the number of tools in the system, and the extent of the change.
     
13. Can you supply forgings made from special alloys?
    Generally, forging of special alloys (ie titanium) requires special processing equipment and forging procedures. Not all forging companies will possess these facilities. In such cases, AFG members will advise which forges are capable of forging these materials. Another problem may be the availability of forging bar stock, as this may need to be imported. Further advice may be obtained from the AFG.
     
14. Do you have a metallurgist on staff?
    Most of the larger forging companies employ a metallurgist. The smaller companies usually do not, but generally rely on metallurgical consultants and advice from the CSIRO.
     
15. Do you have a testing laboratory?
    In general, laboratories with a wide range of testing facilities are usually found in the larger forges. Some of the smaller forges have testing machines capable of proof testing forgings or assemblies. In all instances where forges have testing facilities, these would be part of the quality system, and they would be certified and approved to carry out different classes of test. There are several sub contract testing laboratories that carry out testing work for the industry.
     
16. Is your laboratory approved by NATA?
    Most forging company laboratories and outside contract laboratories are NATA approved, and are able to issue endorsed test certificates.
     
17. What about proof load, and destructive testing of forgings and assemblies?
    Those forges producing load-bearing items such as fasteners, shackles, eyebolts and hooks etc., would have dedicated load-testing machines. In these instances, the capability is available (apart from fasteners), to carry out 100% proof loading. These tests would be in accordance standard specifications or to specific requirements as specified by the customer.
     
18. I require grain flow sections to verify that the metal flow will result in optimum properties being developed in my forgings. Can you carry out this work?
    This will not present a problem. Those forges with their own laboratory would be able to carry out this work; the smaller forges would engage the services of an outside laboratory.
     
19. Do you make your own tooling?
    Most forging companies have competent tool rooms capable of making a wide range of tooling. In some cases, tooling may be subcontracted to outside toolmakers. This will depend on the workload in the particular forge's tool shop. There is also a consideration, where a sub contractor may be able to carry out certain types of tool making more economically than the forge, due to the type of equipment at his disposal.
     
20. Do you have a brochure containing information on your company, and it's products?
    Most forging companies have well-illustrated brochures.
     
21. Do you have a design office?
    Depending on size, most forging companies have their own drawing office to design forgings and tooling.
     
22. Does your design office use a CAD system.
    The majority of our members use a computer aided design system for design of forgings and tooling. Unfortunately there has been no standardisation, and several different systems are in use.
     
23. Can you receive electronic transfer of drawings and other data?
    Some of our members can receive electronic transfer of drawings and data. The main constraint is having a system which is compatible with that of the customer.
     
24. Do you have CAD/CAM facilities?
    Several of our members use CAD/CAM facilities for manufacture of tooling. In these instances the tool room is networked to the design office. CAD/CAM machining techniques may be used for machining of forgings where machined product is specified.
     
25. How can I be sure that all forgings in a particular delivery will meet my requirements?
    The quality control system specifies frequency of testing during a production run. It also lays down a procedure for audit testing prior to delivery. If defective forgings show up during production, those forgings made since the last satisfactory production check will be quarantined, and subjected to 100% testing. If defective forgings are found during an audit prior to delivery 100% checking will be carried out on the batch.
     
26. Do you have a minimum ordering quantity?
    This will vary from forge to forge. Set up costs of forging equipment are significant, and need to be recouped during a production run. The smaller the quantity of forgings required, the higher would be the piece price.
     
27. Do you carry stocks of forgings?
    Most forging companies prefer to make and supply against a schedule. In regard to stock, forge management will decide the most economical procedure to apply to a production run, and a decision may be made to run up two or more month's stock. With small production quantities, and in order to spread set up costs, it may be more economical to make three months supply in one run. This would be factored into the original quotation.
     
28. I require a good quality surface finish free from surface blemishes - what can you offer?
    The majority of surface imperfections result from worn dies, and in the case of steel forgings, excessive scale can be a contributory factor. Die lubrication can be another factor. In regard to worn dies, if we could agree on a desired surface finish, this would be used as a standard for production, and would be included in our quality procedure for a particular forging. Scale on steel forgings is attributable to heating techniques, and or deficiencies in the forging process by not taking into account adequate provision for scale removal. Despite our best operating techniques, some amount of scale may be present, and again we need to agree on acceptance standards. Lubrication is not normally a problem, as forges use lubricants, which have been, proved satisfactory on previous production runs. Raw forgings are generally supplied in the shot blasted condition, with surface finish dependent on the type and size of shot used.
     
29. Can you offer 100% crack detection of my forgings?
    Most forging companies can offer magnetic crack detection for steel forgings, and dye penetrant crack detection for non-ferrous metals. Where a particular forge does not possess facilities for crack detection, this process is sub contracted.
     
30. How can I be confident, that my forgings will not be overheated?
    Overheating results from high forging temperatures, and or excessive time at temperature. The forging temperatures for particular metals are well known and are expressed as a range. For example, the forging temperature of a particular steel grade may be 1250 to 1300 deg.C. Forges would tend to aim at a mid temperature figure to allow a degree of safety. Additionally, pyrometric control instrumentation is now widely used throughout the industry to ensure safe heating practices.
     
31. I shall be requiring forgings made from stainless steel - what do you know about heat treatment, and passivation of stainless?
    Heat treatment of stainless steels, apart from the precipitation grades, generally falls into two categories, namely annealing or hardening and tempering. Some forging companies have their own heat treatment facilities others would sub contract to approved contractors. In regard to passivation, this treatment is necessary to remove embedded scale, and or iron particles which may cause surface rusting. The process involves an acid treatment to remove these imperfections. Some forges would possess suitable equipment and would make up the necessary solutions as required. Others would prefer to sub contract.
     
32. Do you carry stocks of forging bar?
    For reasons of economy, we aim to keep our stocks of forging bar at minimum levels. Where a customer has delivery schedules, we will maintain up to three months stock if the material is not readily available. Most of our suppliers are able to support us with monthly or better deliveries of bar stock.
     
33. I require my forgings to be supplied as finish machined product - do you have your own machining facilities?
    Most forges have machining facilities and are able to supply some product fully machined. However, with the availability of specialised machine tools, all forges would investigate outside contract sources to ensure that best possible prices were obtained.
     
34. Can you offer a heat treatment service?
    A number of forges have a wide range of heat treatment facilities and are able to offer a variety of services. Other forges have strong associations with contract heat treaters, where suitable work would be carried out.
     
35. What is your standard packing procedure for dispatch of forgings?
    Rough forgings are normally delivered in strong boxes on pallets for forklift handling. Machined product would be individually packed to prevent damage. If you require a special procedure for packing and dispatch, this can be accommodated.
     
36. Do you have a software package for simulation of the forging process?
    Ideally, tryout of the forging method should be done on the computer before committing forge equipment to production. At this stage, with the exception of one company, Australian forges have been slow to embrace this technology.
     
37. Do you have an e-mail address?
    Most Australian forges have this facility, others will implement this technology in time. (see individual member pages for contact details)
     
38. What about a web page?
    The AFG is encouraging members to develop a web page, and have provided space on this site for member entries (see above). Apart from supporting the AFG site, several of our members have their own WWW entries, which contain information concerning their own particular company. Where possible, links to member sites are provided on their individual page provided under Group Info/AFG membership.
     
39. For the purpose of maintaining contact I require the names of two individuals in your organisation whom I can contact for information.
    This not a problem. We shall ensure that all personnel nominated will be fully familiar with your requirements.
     
40. What is the situation in regard to terms of payment?
    Most forging companies require payment within 30 days, however this is a matter to be negotiated with individual organisation.

JK Anderson (April 1999)