Upset Forging

Upset Forging is one of the most common methods of forging used in the world to date.

The Upset forging Process

Upset forging is carried out by holding a preheated bar steadily in position then the end of the bar is compressed into a die. Upset forging is basically a manufacturing process that shapes metal into various shapes and sizes using heat and dies.

Upset forging has many capabilities and the sizes that can be made range from 6mm up to 100mm in diameter, these can be formed into many shapes such as square, round, flat, or hexagonal.

There are many benefits of upset forging such as:

No stress areas are created when the metal size needs to be reduced

The grain flow is retained so metal strength is inherent

You will not get fractures at the weld joints

No porosity or brittleness concerns with upset forging

What is Upset Forging used for?

Upset forging is mostly used in the production of bolts and fastener components. The main two processes of upset forging are horizontal split die forging and closed die forging, these two processes are popular and used worldwide.

Some examples of upset forging are:


Squarehead bolts

Hexagon bolts

Anti-roll bars

Torsion bars


Upset forging can also be known as open die forging. There are not many disadvantages to this type of forging but the few we can think of are:


Limited on size because of the press size you use

The maintenance cost of this type of forging can be high

Certain materials can not be forged in this way

Upset Forging