Forging Integrity +
Casting Efficiency
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Aluminum Thixocasting

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.

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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.