Our Process
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OUR PROCESS – METAL INDIA FORGE
Step 1: Raw Material
Metal India Forge sources premium-quality raw materials from trusted and certified suppliers. Our range includes Alloy Steel, Carbon Steel, Stainless Steel, Duplex and Super Duplex Stainless Steel, Nickel Alloys such as Inconel, Monel, Hastelloy, as well as Forging Ingots and Billets. Every material batch comes with a Heat Number and Batch Traceability, ensuring full documentation and quality assurance before processing.
Step 2: Raw Material Testing
Each batch undergoes rigorous quality control to ensure compliance with industry standards. Testing includes Spectro Chemical Analysis to verify chemical composition, Ultrasonic Testing (UT) for internal defects, Hardness Testing, and Dimensional Verification. Only materials meeting strict criteria are approved for further processing.
Step 3: Cutting
Approved raw materials are cut to the required sizes using Band Saw Machines and CNC Cutting Machines. Precision cutting ensures smooth edges, accurate dimensions, and a perfect starting point for forging.
Step 4: Heating
The cut blanks are uniformly heated to 900–1250°C in advanced Induction or Forging Furnaces. Proper heating ensures a correct grain structure, softens the material for forging, and avoids inconsistencies that could compromise strength.
Step 5: Forging
Heated blanks are shaped into the desired forms using Power Hammers and Hydraulic Forging Presses. Forging enhances the mechanical properties, improves the material’s grain flow, and ensures superior strength and durability for industrial applications.
Step 6: Proof Machining
After forging, components undergo rough or proof machining on CNC and Lathe Machines to achieve pre-final dimensions. This step ensures uniformity and prepares the parts for accurate heat treatment and final machining.The cut blanks are uniformly heated to 900–1250°C in advanced Induction or Forging Furnaces. Proper heating ensures a correct grain structure, softens the material for forging, and avoids inconsistencies that could compromise strength.
Step 7: Heat Treatment
Components are subjected to various heat treatment processes depending on material and customer requirements. These include Normalizing, Annealing, Quenching & Tempering, Solution Annealing, and Case Hardening. Hardness testing follows each process to ensure the required mechanical properties are achieved.
Step 8: Machining
Final machining is carried out on precision CNC, VMC, and Turning Centers. Tight tolerances (up to ±0.01 mm) are maintained to ensure high dimensional accuracy and a smooth finish suitable for critical applications.
Step 9: Testing
Components undergo rigorous testing including Magnetic Particle Inspection (MPI), Ultrasonic Testing (UT), Hardness Testing, Tensile Testing, Impact Testing, and PMI Testing for alloys. This guarantees compliance with customer and industry standards.
Step 10: Punching
Punching is performed to mark each component with essential identification details such as the Heat Number, Batch Number, Grade, Size, and Customer Code. This ensures complete traceability throughout the entire manufacturing and supply process.
Step 11: Final Inspection
After punching, every component undergoes a detailed Final Inspection. Dimensional accuracy, surface finish, and overall quality are thoroughly checked to ensure that only defect-free and fully compliant components move forward for packing.
Step 12: Packing
Approved components are then packed with utmost care using Rust Preventive Oil, HDPE/Bubble Wrapping, Wooden Boxes, Pallets, or Export-grade packing as required. This ensures maximum protection during handling, storage, and transportation.
Step 13: Dispatch
Once packing is completed, the products are dispatched on time with complete documentation and safety measures. Our logistics ensure secure, efficient, and reliable delivery to customers across India and international markets.