Forging in New Hampshire

New Hampshire forges employ both open-die and closed-die techniques, selected based on part geometry, volume, and material requirements. Open-die forging—using flat or shaped dies with pneumatic or hydraulic hammers—dominates for larger, lower-volume components like turbine shafts, pump bodies, and custom brackets where the forging sequence is tailored to each part. This method excels when grain structure control and metal flow are critical, as the forger can manipulate material directionally through multiple heating and striking cycles. Closed-die (drop-forge) work is common for higher-volume aerospace and automotive components: fasteners, small brackets, and precision flanges where cavity definition and repeatability matter. Many NH forges use CNC-controlled forging presses, which improve consistency and reduce scrap compared to manual hammer work. Hot isotatic pressing (HIP) capabilities are available at larger facilities, eliminating internal porosity in premium aerospace forgings. Process control is rigorous: digital thermometry ensures material reaches proper forging temperature before working, in-process hardness testing validates mechanical properties, and ultrasonic or magnetic particle inspection catches surface and subsurface defects before finishing.

NH forges handle a broad alloy palette reflecting their aerospace and industrial customer base. Carbon steels (1020, 4140, 4340) are foundational for industrial equipment and lower-stress aerospace components. Alloy steels like 300M and 9310 support landing gear, fasteners, and drivetrain components requiring high fatigue resistance. Stainless steels (300M, 15-5PH, 17-4PH) serve corrosion-sensitive and elevated-temperature applications. Nickel-based superalloys—Inconel 718, Inconel 625, Waspaloy—are forged for engine components and extreme-environment fasteners, though these demand specialized furnace control and experienced forgers (material costs are high, and process mistakes are expensive). Aluminum forgings (7075-T73, 2024-T4) round out the portfolio, though fewer NH shops have aluminum forging capabilities due to different tooling and thermal requirements. Copper alloys and titanium (Ti-6Al-4V) are less common in NH forges but available through specialty shops. Material sourcing is typically performed by the forger: they purchase raw ingot stock or billet from domestic mills (Carpenter Technology, Allegheny Technologies) and maintain certification documents proving composition and cleanliness.

Quality expectations in aerospace and defense forging are uncompromising, and NH forges structure their operations around traceability and statistical process control. ISO 9001 certification is standard; most aerospace-serving shops also maintain AS9100 certification (the aerospace quality standard that layers on top of ISO 9001). NADCAP accreditation in special processes—specifically heat treatment (AMS 2750 compliance) and sometimes nondestructive testing—signals third-party validation that processes are documented, monitored, and capable. In-house inspection labs use hardness testers (Rockwell, Brinell), tensile test machines, and optical microscopy to validate mechanical properties. Larger forges employ ultrasonic flaw detection (UT) and magnetic particle inspection (MPI) to identify internal defects and surface cracks; some have X-ray capabilities for critical parts. Digital traceability is increasingly standard: serial numbers or heat codes are stamped on forgings, linked to material certs, process records, and inspection reports that customers can access. First Article Inspection Reports (FAIRs) are routine for new programs—customers receive documented evidence that the first production forgings meet all prints before bulk production begins.