title = "Forging Defects: Types, Causes, and Inspection"

content = """
Forging defects can compromise the structural integrity of components and must be identified and dispositioned before parts advance to downstream operations. At Ridgecrest Metalworks, first-piece and in-process inspection programs are designed around the known defect modes of each forging process.

Laps and folds are surface defects caused by metal folding back on itself during forging. They typically appear as tight linear seams on the part surface. Laps form when excess metal is squeezed out and then folded over by subsequent die closure, or when a preform stage incorrectly places metal that then folds in the finish die. Laps can penetrate deeply into the part and cannot be removed by surface grinding alone; affected forgings are scrapped.

Cold shuts are similar to laps but form when two fronts of flowing metal meet without completely fusing, leaving an internal or surface seam. They are caused by inadequate die temperature, insufficient forging pressure, or poor metal flow path design.

Underfill occurs when the die cavity is not completely filled, leaving low or missing sections on the forging. Causes include insufficient billet volume, too-cold billet, inadequate forging force, or worn dies with enlarged flash gaps that allow metal to escape too easily.

Flash cracking occurs at or near the parting line when flash is trimmed; cracks can extend into the part body. This results from trimming at too low a temperature when the metal is brittle, or from excessive notch sensitivity at thin flash regions.

Internal cracking (bursts) results from excessive tensile stress developing inside the forging during deformation, often in large sections or alloys with low hot ductility. They are detected by ultrasonic testing.

Grain flow irregularities—where the fiber structure of the forging does not follow the part contour—reduce fatigue strength. Macro-etch tests reveal grain flow in sectioned samples.

Inspection methods include visual inspection (surface defects, dimensions), magnetic particle inspection for surface and near-surface cracks in ferrous forgings, liquid penetrant inspection for non-ferrous alloys, ultrasonic testing for internal defects and cracks, and dimensional checks using CMM or hand tools against the forging drawing.
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