Forging Integrity +
Save Weight & Cost
Tool Design & Build
Onsite tool shop, EDM, CNC
SolidWorks CAD Modeling
1 to 8 cavities designs common
9 out of 10 tools built in-house
Quick turns compress the build cycle
12 weeks typical, 8 weeks w/expedite
Continuous thixotropic bar casting
Semi-solid metal thixocasting
Heat-treatment T5 and T6
CNC 3- & 4-axis machining
Cosmetic surface finishing
Stainless steel and glass bead blasting
Manual & DCC CMM inspection
Finishes & Coatings
Electroless nickel & chrome plating
Chromate / Chem film
Local & regional supply base
Vforge, Inc. supplies world-class OEMs in the aerospace, medical, transportation, recreation and industrial markets of North America, Asia and Europe. We manufacture unique aluminum parts from 5 g to 5 lbs. and at quantities from 150 to 250,000 pieces per year. Our clients source for lower total manufacturing cost by rethinking traditional forgings, extrusions and machined parts to benefit from our near-net, fully dense process, or by replacing castings prone to costly porosity, field failure or dimensional instability.
We start with premium grade aluminum ingot. Material heats are alloyed, filtered, degassed, electromagnetically stirred and continuously cast as cylindrical bar to produce and control the equiaxed grain structure that enables our high-integrity, semi-solid metal (SSM) thixocasting process. Billets are cut, preheated to induce thixotropy, then injected, turbulence-free, into isothermal dies. Material solidification occurs under high consolidation pressure to yield fully dense, near-net shape, heat-treatable parts with peak mechanical properties that conform to NADCA precision tolerance standards.
CT x-ray scans reveal the high integrity of the semi-solid metal thixocasting process.
This industrial valve must be fully dense to pass high pressure testing after machining.