Forged round bar
The most common form; for shafts, axles, piston blanks, rollers and rotating parts. Supplied black (as forged), rough turned or peeled.
Open-die forged bar stock
Forged Aluminium Bar: Round, Square and Rectangular
Forged aluminium bar is made by working a cast ingot between open dies until the whole cross-section is wrought, giving sound metal and even properties in sizes larger than extruded or rolled bar can reach. It is the usual starting stock for heavy shafts, aircraft fittings, landing-gear parts and large machined components. Metline supplies forged bar in 6061, 7075, 7050, 2024, 2014, 2219 and other alloys, heat treated and certified to AMS, ASTM or EN, to customers worldwide.
- Shapes
- Round, square, rectangular, stepped
- Alloys
- 6061 · 7075 · 7050 · 2024 · 2014
- Tempers
- T6, T652, T73, T7352, T7452
- Standards
- ASTM B247 · AMS · EN 586
What is forged aluminium bar?
Forged bar is a hand (open-die) forging in a simple bar shape. A homogenised ingot is heated and repeatedly pressed, rotated and drawn out between flat or V-shaped dies until it reaches the required section. The process is sometimes called cogging.
Why not simply buy extruded or rolled bar? For small and medium diameters, extruded rod is cheaper and perfectly adequate. Forged bar earns its place in three situations: when the diameter is beyond the practical range of extrusion presses (large rod is commonly limited to roughly 300 – 400 mm); when the specification calls for a forging and its specific test directions; and when the part needs good properties through the whole section, not only along the length. Forging works the centre of the ingot as well as the surface, closing porosity and breaking up the cast structure where extrusion of very large sections can leave it under-worked.
Forged bar also avoids a problem common in extruded 2xxx, 7xxx and 6082 rod: a coarse recrystallised grain ring near the surface, which can lower fatigue strength and spoil the appearance of anodised parts. A properly forged and heat-treated bar has a more uniform grain structure from surface to core.
Forged bar shapes and blanks
Forged square bar
For tooling bases, fixtures and blocks that will be milled on all faces.
Forged rectangular bar
For long fittings, rails, spars and machine members where width and thickness both matter.
Stepped and tapered bar
Shafts and blanks forged with different diameters along the length to reduce machining and keep grain flow continuous.
Large-diameter bar
Heavy sections for hubs, rollers and structural parts where the whole section carries load.
Cut lengths and slices
Bar sawn into blanks or discs to the customer's finished-part envelope.
Forged bar alloys and where they are used
| Alloy | Common tempers | Character | Typical forged-bar parts |
|---|---|---|---|
| 6061 | T6, T652 | Medium strength, very good corrosion resistance, weldable | Shafts, frames, vacuum and semiconductor parts, general CNC parts |
| 6082 | T6 | Slightly stronger than 6061, European standard choice | Machinery shafts, rail and crane components |
| 7075 | T6, T652, T73, T7352 | Very high strength; T73 tempers resist stress corrosion | Aircraft fittings, defence parts, high-load tooling |
| 7050 | T74, T7452 | High strength in thick sections, low quench sensitivity, good SCC resistance | Thick aircraft fittings, landing-gear and bulkhead parts |
| 2024 | T4, T6, T852 | High strength and fatigue resistance | Aircraft fittings, fatigue-loaded shafts |
| 2014 | T6, T652 | High strength, good forgeability, economical | Heavy brackets, truck and aircraft components |
| 2219 | T6, T852 | Keeps strength at elevated and cryogenic temperatures; weldable | Rocket and cryogenic tank parts, hot-running components |
| 4032 | T6 | High silicon, low thermal expansion, wear resistant | Forged pistons and compressor parts |
| 5083 | O, H112 | Excellent seawater and cryogenic performance, weldable | Marine shafts, cryogenic and pressure parts |
The 7xxx choice deserves care. 7075-T6 is the strongest but is prone to stress-corrosion cracking when loaded across the grain; for structural parts, T73 or T7352 is normally specified. In sections thicker than about 75 – 100 mm, 7050 keeps more of its strength at the centre because it is less quench-sensitive.
Typical mechanical properties of forged bar alloys
Values are typical for the alloy and temper in the longitudinal direction. Forging specifications set lower guaranteed minimums that fall as the section gets thicker and are lower again in the transverse directions. The certificate reports the actual results against the ordered specification.
| Alloy and temper | Tensile strength | Yield strength (0.2 %) | Elongation | Density |
|---|---|---|---|---|
| 6061-T6 | 310 MPa / 45 ksi | 276 MPa / 40 ksi | 12 % | 2.70 g/cm³ |
| 6082-T6 | about 330 MPa | about 280 MPa | 10 – 12 % | 2.70 g/cm³ |
| 2014-T6 | 483 MPa / 70 ksi | 414 MPa / 60 ksi | 13 % | 2.80 g/cm³ |
| 2024-T4 | 469 MPa / 68 ksi | 324 MPa / 47 ksi | 19 % | 2.78 g/cm³ |
| 2219-T6 | 414 MPa / 60 ksi | 290 MPa / 42 ksi | 10 % | 2.84 g/cm³ |
| 4032-T6 | 379 MPa / 55 ksi | 317 MPa / 46 ksi | 9 % | 2.68 g/cm³ |
| 7075-T6 | 572 MPa / 83 ksi | 503 MPa / 73 ksi | 11 % | 2.81 g/cm³ |
| 7075-T73 | 505 MPa / 73 ksi | 435 MPa / 63 ksi | 13 % | 2.81 g/cm³ |
Thick forged bar always has lower guaranteed properties at the centre than thin sections, particularly in quench-sensitive alloys such as 7075 and 2014. Ask for test locations representative of the finished part.
Specifications for forged aluminium bar
| Specification | Scope |
|---|---|
| ASTM B247 / B247M | Die forgings, hand forgings and rolled rings: general and aerospace use |
| SAE AMS 4127 | 6061-T6 forgings |
| SAE AMS 4126 | 7075-T6 forgings and rolled rings |
| SAE AMS 4141 | 7075-T73 die forgings |
| SAE AMS 4107 / AMS 4108 | 7050-T74 die forgings / 7050-T7452 hand forgings |
| AMS-QQ-A-367 / AMS-A-22771 | General requirements and heat treatment for aluminium forgings |
| EN 586-1/-2/-3 | European forgings standard: delivery, properties and tolerances |
| ASTM B594 / AMS-STD-2154 | Ultrasonic inspection of aluminium wrought products |
Aerospace bar is usually ordered to an AMS specification or an airframer standard that refers to them. Industrial bar is commonly ordered to ASTM B247 or EN 586. Give us the exact specification and revision and we will confirm compliance, test directions and documents before quoting.
Sizes and weights of forged round bar
Forged bar is made to order, so sizes are set by the finished part rather than a stock list. Round bar is typically supplied from around 100 mm diameter, where it starts to compete with extruded rod, up to very large diameters for heavy shafts and hubs; lengths are limited by ingot weight and handling. Send the finished dimensions and we will confirm the forged size and allowance.
| Diameter | 6061 (kg/m) | 7075 (kg/m) |
|---|---|---|
| Ø 100 mm | 21.2 | 22.1 |
| Ø 150 mm | 47.7 | 49.7 |
| Ø 200 mm | 84.8 | 88.3 |
| Ø 250 mm | 132.5 | 137.9 |
| Ø 300 mm | 190.9 | 198.6 |
| Ø 350 mm | 259.8 | 270.4 |
| Ø 400 mm | 339.3 | 353.1 |
| Ø 500 mm | 530.1 | 551.7 |
| Ø 600 mm | 763.4 | 794.5 |
| Ø 800 mm | 1357.2 | 1412.5 |
Theoretical weights for the nominal diameter: kg/m = π/4 × d² (mm) × density (g/cm³) / 1,000. As-forged bar carries a machining allowance, so its actual weight is higher than the finished size.
How forged bar is made and delivered
- Ingot preparationHomogenised ingot is scalped to remove surface segregation and cut to weight.
- Open-die forgingThe ingot is heated and drawn out on a hydraulic press, often with upsetting to work it in more than one direction. A minimum reduction ratio is commonly specified to break down the cast structure.
- Heat treatmentSolution treatment, quench and ageing; T652, T7352 and T7452 add controlled compression to relieve quench stress so the bar stays stable during machining.
- ConditioningSawing to length, rough turning or peeling, centre drilling and end marking as required.
- Inspection and dispatchTesting, certification and export packing.
Delivery conditions
- Surface
- As forged (black), rough turned or peeled
- Ends
- Saw cut, chamfered or centre drilled
- Marking
- Alloy, temper, heat or lot number, specification
- Machining services
- Cutting to length, slicing into discs, rough machining to drawing
Testing and certification
Typical inspection plan
- Chemistry
- Heat analysis to the Aluminum Association / EN 573-3 limits
- Tensile tests
- Longitudinal and transverse directions as required, from bar prolongations
- Hardness and conductivity
- To confirm temper, especially over-aged 7xxx tempers
- Ultrasonic testing
- To ASTM B594 or AMS-STD-2154, class as ordered
- Macro and micro examination
- Grain size, flow and freedom from cast structure
- Dimensional
- Diameter, straightness and length
- Certificate
- EN 10204 3.1 with chemistry, heat treatment and test results; third-party witness on request
Metline operates an ISO 9001 certified quality management system. State inspection and testing requirements at the enquiry stage so they are built into the quotation and the forging plan.
Forged bar compared with extruded and rolled bar
| Factor | Forged bar | Extruded rod | Rolled or drawn bar |
|---|---|---|---|
| Size range | Large sections, beyond extrusion limits | Small to medium diameters | Small diameters and flats |
| Centre soundness | Fully worked through the section | Good; very large sizes can be under-worked | Good |
| Grain structure | Uniform; no peripheral coarse grain ring | Coarse grain ring possible in 2xxx, 7xxx, 6082 | Fine |
| Transverse properties | More uniform | Strongly directional | Directional |
| Tolerance | Needs machining allowance | Close as extruded | Close |
| Cost | Higher | Lowest | Low |
For standard diameters, extruded bar such as 6061 round bar or 7075 rod is the economical choice. Move to forged bar when size, specification or through-section properties demand it.
How to order forged aluminium bar
- SpecifyAlloy and temper, shape, finished and forged dimensions, length, quantity, specification and revision.
- TestingTest directions, UT class, conductivity and any third-party inspection.
- ProposalWe confirm the forging size, allowance, heat-treatment route and inspection plan.
- CertificationEN 10204 3.1 certificate, UT and dimensional reports with the shipment.
- ShippingBar wrapped, crated or skidded for export; EXW, FOB, CIF or DAP.
References and standards
- ASTM B247 – Aluminum and Aluminum-Alloy Die Forgings, Hand Forgings, and Rolled Ring Forgings
- SAE AMS 4127 – Aluminum Alloy Forgings, 6061-T6
- SAE AMS-QQ-A-367 – Aluminum Alloy Forgings
- EN 586-2 – Aluminium and aluminium alloys: forgings, mechanical properties
- ASM Handbook, Vol. 2 – Properties of Wrought Aluminum and Aluminum Alloys
Forged aluminium (aluminum) bar: frequently asked questions
What is the difference between forged and extruded aluminium bar?
Extruded bar is pushed through a die and has strongly directional properties; it is economical in small and medium diameters. Forged bar is worked between open dies from an ingot, reaches larger sizes and has more uniform properties through the section.
What sizes of forged aluminium bar can you supply?
Forged bar is made to order from the finished-part size. Round bar typically starts around 100 mm diameter and goes up to large heavy sections; send your dimensions and we will confirm feasibility and the forged size.
Which temper should I order for 7075 forged bar?
T7352 for structural parts that will be heavily machined or loaded across the grain, because it resists stress-corrosion cracking and is stress relieved. T6 or T652 only where maximum strength is needed and SCC risk is low.
Is forged bar supplied machined?
It can be supplied as forged, rough turned or peeled, cut to length or rough machined to your drawing.
Which specification covers forged aluminium bar?
ASTM B247 and EN 586 for general use; AMS specifications such as AMS 4127 (6061-T6) and AMS 4126 (7075-T6) for aerospace.
Is ultrasonic testing included?
It can be. Ultrasonic inspection to ASTM B594 or AMS-STD-2154 is specified per order, with the class stated on the purchase order.
Need forged aluminium bar?
Send the alloy, temper, size and specification. We will confirm the forged size, testing and delivered price.
