May 2026 Volume 8

EQUIPMENT & TECHNOLOGY

THE CRITICAL ROLE OF FORGINGS IN THE DEFENSE INDUSTRY By Darren Bogenschutz

Strength, Reliability, and Readiness Where It Matters Most In the defense industry, reliability isn't just a goal; it is crucial. Components for ground combat vehicles, naval propulsion systems, aerospace platforms, and weaponry must perform dependably in tough conditions that test both materials and design integrity. These parts need to withstand high loads, hostile environments, and long service lives that often exceed initial expectations. Defense systems are quite different from commercial products because they face shocks, vibrations, extreme temperatures, corrosion, and sometimes direct combat damage. Many platforms remain operational for decades and receive multiple upgrades and extensions. As a result, selecting appropriate materials and manufacturing methods is just as important as the design itself. Traditionally, forging processes have been used to meet these demanding requirements. However, ongoing supply chain issues and geopolitical uncertainties have heightened the focus on readiness, local manufacturing, and proven production techniques. Industry experts highlight a key point: maintaining strong domestic forging capacity is essential for ensuring defense readiness. Why Forgings Matter in Defense Applications Forging distinguishes itself from other metal forming techniques through its unique internal shaping process and external modifications. It creates a superior, directional grain flow that follows the shape of the component, which improves load capacity and resistance to crack initiation and propagation. Unlike components made from bar stock, which typically have a linear grain structure regardless of shape, or cast parts that may contain porosity and internal defects, forgings provide excellent internal integrity and continuous grain flow along critical load paths. These qualities result in better strength-to-weight ratios, increased fatigue resistance, and enhanced toughness against impact and fracturing. Extensive failure analysis in high-stress systems indicates that fatigue is a leading cause of mechanical failure. In defense applications, where cyclic loads, shocks, and heavy torque are common, strong resistance to fatigue and crack growth is essential.

and hardware for artillery and weapon systems. They are also essential for propulsion system parts, engine mounts, and aerospace structural components. Often, forged parts form the structural backbone of assemblies, directly affecting overall system performance and longevity. In cases where repairs or replacements are difficult during operations, the consistent internal quality of forged components provides confidence that other manufacturing methods can't easily match.

Photo Credit (left to right): U.S. Army / Joseph Trevithick / HII

Closed Die Forging and Modern Defense Requirements

Closed die forging provides significant advantages for modern defense applications requiring intricate shapes, tight tolerances, and consistent quality. This process enables the production of near-net shape parts, minimizing extensive machining while maintaining a favorable grain structure. Unlike parts fully machined from bar stock, near-net forgings significantly reduce material removal and machining time, leading to better cost predictability and higher production efficiency without compromising performance. From a design standpoint, closed die forging enables engineers to strategically allocate material where it is most necessary, optimizing wall thickness, transitions, and load-bearing features. This flexibility supports defense initiatives focused on vehicle mobility, payload capacity, fuel efficiency, and extended operational range. In both ground vehicles and aerospace systems, the ongoing challenge of reducing weight while preserving strength makes forging a reliable solution.

Common Defense Applications for Forged Components

Supporting Long Life Defense Platforms Defense platforms are built for longevity, often functioning for many decades. Throughout their lifespan, they may be upgraded, modernized, or reconfigured, increasing the need for supporting components. Their long service life highlights the importance

Thanks to their exceptional performance and reliability, forgings are vital for defense platforms. Typical uses include transmission gears and shafts, axle and suspension parts, track systems,

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