Open Die Forgings, also known as “Hand Forgings” or “Forged Block,” are manufactured using flat dies that eliminate the need for specialized tooling. This versatile process creates custom shapes while maintaining superior grain structure and mechanical properties. These components feature specific grain directions—Short Traverse (ST), Long Traverse (LT), and Longitudinal (L)—optimized for each application’s stress requirements.
APP produces open die forgings beyond traditional “block” shapes, including bent, stepped, and curved geometries. This flexibility makes open die forging ideal for low-volume production and specialized applications without custom tooling expenses. The resulting components deliver exceptional strength for critical aerospace, defense, and industrial applications.
Advantages of Open Die Forgings
Open die forgings offer several key benefits for specific manufacturing scenarios. When the cost of developing closed die forging tools is prohibitive, open die forging provides an economical alternative. This approach is ideal when engineering specifications aren’t yet finalized, making closed die tooling premature. For components requiring forged material properties where machining from open die stock is the most cost-effective solution, this method excels. Additionally, when tight program timelines don’t allow for closed die tooling development, open die forgings can meet critical deadlines.
APP offers a wide range of open die forging capabilities at both our Santa Ana and Oxnard facilities in California, including production of special shapes and round hollows (trepanned and/or bored). Our expertise can help determine if your component is an ideal candidate for open die forging.
Materials and Capabilities
APP processes numerous aluminum alloys for open die forgings, including 2014, 2024, 2219, 2618, 3003, 4032, 5083, 5086, 6061, 7049, 7050, 7075, 7079, 7149, 7150, 7175, 7249, and others. We offer all available tempers including -F, O, -01, all T tempers and H tempers, including stress relieved options (-T7352, T7452, etc.), with specific alloys requiring specific tempers.
Our comprehensive in-house services include precision machining of rectangular surfaces to tolerances of +.010/-.000, mechanical testing, ultrasonic inspection, and stress relief where required. Size capabilities include maximum weights up to 6,000 pounds, rectangles up to 24 inches (ST), 48 inches (LT), and 360 inches (L), biscuits up to 48 inches diameter, and rounds up to 30 inches diameter and 150 inches length.
Get in Touch – We’re Here to Help!
Have questions about our precision forging solutions? Our team is ready to discuss your specific needs and provide tailored expertise. Contact us today to discover how APP’s industry-leading capabilities can support your next project.
