Quality Control

Quality control is the most important aspect in guaranteeing the reliability of copper forgings. CFS Forge is your #1 source for copper forging and machining. We offer a wide variety of in-house forging quality verification and product testing services (such as NDT) designed to provide our customers with the highest quality copper forging product. No matter what the intended application, every copper forging component is examined, inspected, and approved before delivery. Below are the main aspects on quality control of copper forgings:

Design Confirmation

As all the copper forgings produced are customized components, so after the order is placed, all the details on the designed drawings (like material, dimensional tolerance, ect) should be confirmed again with customers. In case there is any misunderstanding, which may cause unnecessary losses.

Material Inspection

According to the dimensions of the copper forged part, we will order copper alloys with right specification from material factory. Although the material certificate is supplied together with materials, it is necessary to test the material compositions again to ensure each element is within the range. The spectrometer in CFS Forge can test the chemical composition exactly, and relevant material report will be sent to our customer to prove the material used.

Besides the inspection of material specification, we will also double check the dimensions of the copper bars ordered before stocking them. Once there is any mistake, we will send back to the material factory and rebook.

Quality Control of copper forgingsDimensional Tolerance Inspection

Dimensional tolerance inspection is also very important. Only qualified copper forgings with correct dimensions can be shipped to our customers. In CFS Forge, our workers normally forge 8 hours per shift, which can forge around 3000pcs-4000pcs. During each shift process, three times inspection on the dimensions are required, which is initial inspection, in-process inspection and final inspection. This will ensure that the dimensions of copper forgings made in our factory are all good. Any quality problem on dimensions is not allowed.

For machined copper forgings with closer tolerance, we will use CMM to test the dimensions. Besides, a set of customized testing gauge is applied to test the dimensions.

Appearance Inspection

Appearance inspection is also nonnegligible, especially for those copper forgings with special surface treatment. Although the quality of copper forging is much better than that of copper casting, it can also occur defects like scratch in copper forging process. So, our quality inspector will check the appearance of copper forging carefully, and pick out the ones with any surface defect.

Mechanical Properties Inspection

To confirm the properties of copper forgings are correct, mechanical testing is performed to approve the copper forgings. The testing confirms the properties comply per the specified mechanical requirements. The below mechanical properties testing is done to confirm proper forging quality.

  • Hardness testing: A non-destructive procedure that demonstrates the copper alloy’s machinability and wear resistance.
  • Tensile testing: A destructive forging quality test that provides ultimate tensile strength, yield strength, elongation and reduction of the material test specimen.
  • Load testing: This test is performed on the entire forging lot to evaluate its forging quality, and to verify that copper forgings can carry (deflect) the required or specified structural load when applied.

Non-Destructive Testing

CFS Forge performs non-destructive casting quality testing (NDT) on-site, which allows us the capability of assuring the quality of copper forging without destroying it. Our NDT in-house facility is fully staffed with both Level II and Level III resident technicians. We are also NADCAP Certified in Dye (Liquid) Penetrant Testing, Magnetic Particle Inspection, and Radiographic (x-ray) Inspection. The on premise NDT facility allows our company to perform the most common combinations of non-destructive testing and inspection methods required by many high-profile industries, such as Aerospace. Each industry has its own set of inspection criteria, or allowance, for defects noted by Class and Grade. The most common methods available are Dye (Liquid) Penetrant Testing, Magnetic Particle Inspection and Radiographic (x-ray) Inspection.