This article discusses the operation of upset forging machines and selection of the machine size. It describes several types of upsetter heading tools and their materials. The article reviews the cold shearing and hot shearing methods for preparing blanks for hot upset forging. It deals with various upsetting processes: offset upsetting, double-end upsetting, upsetting with sliding dies, upsetting pipe and tubing, and electric upsetting. The article also provides information on hot forging and cold forging.

Forgings are classified in various ways, beginning with the general classifications open die and closed die. They are also classified according to how they are made; such as hammer upset forgings, ring-rolled forgings, and multiple-ram press forgings; and in terms of the close-to-finish factor or amount of stock that must be removed to satisfy the dimensional and detail requirements of the finished part. In addition to types and classifications, the article discusses critical design factors and ways to ensure that the resulting forgings measure up to metallurgical, mechanical property, and dimensional accuracy requirements. The responsibility for design verification is vested in material control, which depends on the proper application of drawings, specifications, manufacturing process controls, and quality assurance programs. The article addresses each of these areas as well as related topics; including stress-induced fatigue failure, tolerances, machining allowances; and the fundamentals of hammer and press forgings, hot upset forgings, and hot extrusion forgings.

Flash welding, also called flash butt welding, is a resistance welding process in which a butt joint weld is produced by a flashing action and by the application of pressure. The flash welding process consists of preweld preparation, flashing, upsetting (forging), and postweld heat treatment. This article provides an overview of both flash welding and upset welding and describes the various process and failure origins of flash welding as well as the equipment used. It also explains the characteristics and advantages of solid-state upset welding.

Forging machines use a wide variety of hammers, presses, and dies to produce products with the desired shape, size, and geometry. This article discusses the major types of hammers (gravity-drop, power-drop, high speed, and open-die forging), and presses (mechanical, hydraulic, screw-type, and multiple-ram). It further discusses the technologies used in the design of dies, terminology, and materials selection for dies for the most common hot-forging processes, particularly those using vertical presses, hammers, and horizontal forging machines. A brief section is included on computer-aided design in the forging industry. Additionally, the article reviews specific characteristics, process limitations, advantages, and disadvantages of the most common forging processes, namely hot upset forging, roll forging, radial forging, rotary forging, isothermal and hot-die forging, precision forging, and cold forging.

Forging is the process of working hot metal between dies, usually under successive blows and sometimes by continuous squeezing. This article describes the material selection criteria, quality assurance tests for forged components, and the dimensional tolerances of closed-die steel forgings. It provides an overview of the mechanical properties of wrought materials. The article also includes information on the fundamentals of hammer and press forgings and the design of hot upset forgings.

This article focuses on the forging behavior and practices of carbon and alloy steels. It presents general guidelines for forging in terms of practices, steel selection, forgeability and mechanical properties, heat treatments of steel forgings, die design features, and machining. The article discusses the effect of forging on final component properties and presents special considerations for the design of hot upset forgings.