August 2025 Volume 7

EQUIPMENT & TECHNOLOGY

A s the forging industry continues to evolve under the pressures of advanced applications, economic fluctuations, and a tightening labor market, material and tooling suppliers are at the forefront of innovation. In this month’s cover story, FIA explores the latest trends shaping forging materials and tooling technologies—from the rise of ultra-clean alloys to quick-change die systems and evolving customer demands. THE LATEST TRENDS IN MATERIALS AND TOOLING TECHNOLOGY By FIA Staff

The Importance of Early Material Selection Material selection has become a strategic decision that can significantly affect downstream success. Oettli cautioned that many quality certifications can be vague or incomplete when it comes to cleanliness or soundness. “Customers should be careful when interpreting quality statements on certifications,” he said. “Claims about bearing or aircraft quality must be verified to ensure fitness for demanding applications.” McIntosh added that assumptions based solely on generic specs can lead to issues later in the process: “It’s important to understand and communicate end-use requirements so that appropriate processing and inspection can be selected.”

Forging Materials: A Push Toward Precision and Performance High-Performance Alloys on the Rise Over the past 12 to 18 months, the industry has seen a significant uptick in demand for high-performance ultra-clean specialty metals, especially those produced via Vacuum Induction Melting (VIM) and Vacuum Arc Remelting (VAR) processes. These materials, essential for aerospace and defense applications, are driving mill expansions and multi-sourcing efforts. “There is continued growth in high performance ultra-clean specialty metals,” said Graham McIntosh, EVP & CTO at Universal Stainless. “This is particularly evident in the aerospace markets and is leading to both mill capacity expansions and increased multi-sourcing opportunities.” Matt Oettli, Director of Product Management at Metallus, reinforced this trend: “We’re seeing higher demand for vacuum remelt grades specific to defense applications, reflecting overall growth in that sector.” However, he added that the fundamental mix of product types remains largely unchanged—though quoting activity has increased for items previously absent from catalogs, likely due to reshoring or re-sourcing initiatives.

Collaboration and Material Optimization As cost and performance pressures mount, collaboration between forgers and material suppliers is more important than ever. Oettli stressed the importance of early engagement: “There’s still significant opportunity to engineer specific grades of steel to meet requirements in strength, toughness, and corrosion resistance. Lower alloys can sometimes replace expensive stainless grades. That kind of optimization happens through collaboration.” He also noted that more dialogue—not just RFQs—could unlock better solutions: “OEMs and forgers often don’t tap into the institutional knowledge we have. Deeper conversations about material behavior and properties can drive better outcomes for demanding applications like gearing, bearing, and shafting.” Supply Chain Stability—But With Caveats The materials supply chain is relatively stable, according to Oettli. “Lead times are modest and pricing for common grades is stable. Domestic capacity is adequate overall,” he said. However, he warned of broader structural challenges: “Strategic investments in people and production are difficult in the face of variable demand and government policy shifts.” He also highlighted the long-term threat of global overcapacity: “The biggest threat to domestic forging isn’t material availability—it’s finished product from overseas. Countries like India and China are significantly expanding forging capabilities.”

FIA MAGAZINE | AUGUST 2025 14