The Forging Process

Aluminium Alley stock to first forge

The forging process uses high pressure and temperature to change the non-directional grain structure of the cast aluminum starting material to the high integrity multi-directional grain structure of forgings. The aluminum remains solid throughout the process as the forging dies come together and change the shape of the round cast bar to the cylindrical shape of a wheel.
This forged blank is then placed in a custom built spin-forging machine to spin out and forge the rim section. The resulting radial grain direction places the highest material strength in the same direction as the operating loads. The result is 'premium strength'

Finish forge

Turned forge

Next, CNC lathes and milling machines are used to achieve the final configuration.
By making the wheel a forged one piece we have eliminated any possibility of porosity. The world's leading aircraft manufacturers use one-piece forgings for superior performance in critical structural applications. App Tech Forged Wheels uses the same process, combined with over 30 years experience manufacturing aerospace and commercial forged products, to produce aluminum wheels. The result is a high strength, lightweight wheel with no porosity and no welded joints.

Finished product

 

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