Aluminium Forging

Alufora provides “first-time-right” products with our Near Net Shape technology, Lean Product Development approach, progressive and innovative team, and is ready for challenges in new product development, aiming at highest quality, lowest cost and shortest development lead-time. We can produce complex, critical profile forgings with high accuracy due to greater quality control in our in-house die designing processes. This enables us to manufacture dies and tooling to high levels of accuracy. The thermal refining of our products is achieved by employing the Continuous Heat Treatment lines, equipped with facilities for oil/polymer/water quenching and tempering. For thermal treatment of ‘Near Net Shape’ products, we employ controlled atmosphere furnaces. A state of the art phosphating and bonderising facility, takes care of special processes that need to be executed before cold forging operations. Machining facility equipped with high end CNCs, 3, 5 axis VMCs and SPMs enables us to dedicate Machining Lines, consisting of VMCs, CNCs & SPMs for Industry leaders in different segments.

Value analysis and value engineering (VAVE): Alufora executes Value analysis and Value Engineering (VAVE) projects based on customer needs as well as self-initiation using state-of-the-art technologies under one umbrella. VAVE projects have resulted in components with higher strength to weight ratio which is validated for different acceptance criterion using in-house developed balancing software, Finite Element Analysis Methodology and Physical testing.

Light Weighting Greater emphasis of system approach towards light weighting of automotive components through optimizing design, characterization of material properties, wider variety of manufacturing process & use of CAE techniques. This has resulted into lighter, fuel efficient & greener vehicles thus helping us reduce carbon footprints.

Our team is able to create precision forgings with near-finished dimensions to reduce final machining time and minimize waste. Plus, our forgings have grain structures that are superior to the original billet for enhanced strength and performance. All of this results in better components at a lower overall cost for our customers.

We use D-Form simulation software to experiment with different die designs with the goal of optimizing material flow and metal utilization prior to creating our final production dies. We also have in-house fluid-penetrant testing (FPT) equipment to ensure we’re maintaining the highest standards of quality throughout the manufacturing cycle. In addition, we perform CMM dimensional checks in-house to confirm that all of our forgings are within dimensional tolerances throughout the entire production run.

TOOL AND DIE MANUFACTURING At Alufora, we operate our own state-of-the-art tool and die shop in-house at our facility . Here, we’re able to create all of our own forge dies from scratch, depending on the unique needs of the project.

Our tool and die production capabilities enable us to complete new projects quickly and precisely, and we’re pleased to provide valuable design support directly to our customers throughout the process. The ability to design, develop, and produce our own custom tooling and dies truly distinguishes Alufora value proposition from the majority of other forge suppliers.

The aluminum forging process is used in applications where performance and strength are critical requirements. Forged components are commonly found at points of stress and shock. Forged aluminum is ideal for applications where performance and safety are critical but a lighter-weight metal is needed for speed or energy efficiency

The challenging and harsh environments necessitate structures that are strong and durable, but also lightweight. Forged aluminum’s low density relative to steel makes it an ideal candidate for a variety of applications.

Alufora can be your one-stop-shop for all of your aluminum forging needs. We heat treat in house to such tempers as T6, T651, T73 among other custom recipes.

Alufora purchases 100% of its aluminum material from domestic sources.

Alufora can also determine if your billet made part is a good candidate for a conversion to a forging. The net shape of a forging can extensively minimize machining.

We typically forge 2014, 6061 and 7075 series alloys, but have the capability to forge more unique 6000 and 7000 series materials.

Creating the highest quality components from today’s cutting edge aluminum requires precision heat treating equipment. At Alufora, we have our own in-house heat treating capabilities, which enable us to manage the entire process in a controlled environment on site.

By controlling the entire process in house, we eliminate the risk of costly part blemishes that can be caused by transportation to and from outside heat treat vendors. It also means shorter lead times and lower costs for our customers.

Our heat treating equipment includes hardening platforms to T4, T6, T73 and T74. If you have custom heat treating specifications, we always encourage our customers to provide those heating treating specs during the quotation process.

Alufora specializes in precision CNC machining of our in-house produced forgings made from brass, aluminium, and other nonferrous materials. We also can machine parts made from billet material up to 500 mm in diameter in ferrous and nonferrous materials. Our facility is equipped with more than 15 precision machining centers capable of producing quality components to the tightest tolerances for the most demanding applications. We have 10 CNC turning, 4 VMC milling, 1 HMC and a high end precision 5 Axis Machining Center.

Alufora prides itself on offering parts made from billet material and forgings to offer the best manufacturing solutions to our customer’s needs.

Our in-house equipment includes complex computer-controlled multi-axis machining centers capable of automated operation. These automated CNC centers enable us to machine multiple parts at once with high precision in a matter of minutes. Whether the job is simple de-flashing (trimming) or complex 5-axis machining, our expert team and state-of-the-art equipment enable us to get it done with the highest levels of precision.

We have a diverse and distinguished precision machining customer base that includes some of the most renowned manufacturers of electrical components, high voltage electric lugs, wiring devices, marine products, oil&gas components among other industries.

our in-house machining gives us the capability to offer proof or finished machined forgings to customer requirements.

We can carry out a full range of complex or simple machining operations on our forged components.

The benefits of our combined drop forging and machining services are appreciated by customers who want to obtain complete parts from one source, improving communication, quality, lead time and overall cost.

One of the most essential processes for the success of any protective coating system is proper Surface Preparation. The importance of removing salt, oil, grease, old coatings and surface contaminants (such as mill scale and rust on steel and zinc salts on galvanised surfaces) cannot be over emphasised. The performance of any paint coating system is directly dependent upon the performance of preparation of the surface prior to coating. Even the most expensive and technologically advanced coating system will fail if the surface preparation is incorrect or incomplete.

Abrasive Blasting uses a controlled flow of abrasives mixed with compressed air delivered to the surface of the substrate, to clean the surface and leave a profile. The type of abrasive used varies with the job.

We are equipped with a sophisticated line of machinery, that cater to the most stringent manufacturing demands of our customers. Our manufacturing unit encompasses state-of-the-art CNC (Computer Numerical Control) and other automated machines. The production unit with streamlined process supports flawless and uninterrupted manufacturing operations.

Beside, we also have a well guarded and spacious warehouse for storage of in-coming raw material and finished products. All the products are stored in segregated manner with proper labels. Our warehousing facility enable us to meet the contingency and bulk requirements of the customers within stipulated time frame.