Aluminium Precision & Forged Machined Solutions
Custom Aluminum Forging & Aluminium Machined Parts
Fedele Autocore specializes in high-integrity aluminum forging services, delivering custom lightweight components engineered for maximum structural integrity, high strength-to-weight ratios, and superior fatigue resistance. Our advanced forging facilities utilize closed-die, open-die, and isothermal forging technology to produce critical aluminium precision components for demanding automotive, aerospace, defense, and industrial engineering applications.
Working with high-grade engineering aluminum alloys including 6061-T6, 7075-T6, 2024, 6082, and 7050, we preheat billets under strict temperature control before precision press forming. Unlike cast aluminum parts, forged and aluminium machined parts feature refined continuous grain flow, providing up to 30% higher tensile strength without internal porosity.
From high-volume automotive suspension arms and connecting links to aerospace structural fittings and hydraulic manifold blocks, Fedele Autocore provides end-to-end manufacturing—combining precision die forging, solution heat treatment, 5-axis CNC aluminium machined operations, and 100% CMM inspection for clients across 21 countries.
Key Advantages & Benefits
Aluminum forging offers exceptional strength, reduced weight, and zero internal defects.
High Strength-to-Weight Ratio
Forged aluminum achieves structural strength comparable to steel at one-third the density, dramatically reducing component mass for aerospace and automotive efficiency.
Directional Grain Flow
Deforming hot aluminum realigns grain structure continuously along critical load lines, maximizing impact toughness and resistance to stress corrosion cracking.
Zero Internal Porosity
Unlike casting processes, high-pressure forging completely eliminates gas pockets, voids, and inclusions, ensuring leak-tight structural density for pressure applications.
Superior Fatigue Resistance
Uniform microstructural density and absence of internal flaws grant forged aluminum components exceptional life cycles under severe vibrational loads.
Near-Net Shape Accuracy
Precision closed-die tooling produces near-net shape forgings, minimizing raw material waste and reducing downstream CNC machining cycle times.
Excellent Anodizing Response
Homogeneous metal structure provides uniform surface finish for decorative, protective, and hard-coat Type III anodizing.
Types of Aluminum Forging
Comprehensive aluminum forming technologies tailored to your geometric requirements.
Closed-Die Aluminum Forging
Impression die forging produces complex 3D aluminum geometries with high dimensional repeatability, ideal for medium to high-volume production.
- Suspension arms & control links
- Aerospace structural brackets
- Hydraulic valve blocks
- Tight dimensional tolerances
Open-Die & Ring Forging
Ideal for large aluminum shafts, heavy blocks, and seamless rolled rings requiring customized grain direction without complex tooling.
- Large structural billets & rings
- Marine shafting & flanges
- Custom prototype blocks
- Flexible component sizing
Isothermal Precision Forging
Dies maintained at the exact temperature of the aluminum billet allow near-net shape forming with micro-fine detail and zero thermal shock.
- Aerospace impeller blades
- Thin-walled structural parts
- Ultra-fine grain structure
- Minimal machining allowance
Aluminum Cold & Warm Heading
Forming aluminum wire and rod at room or warm temperatures to manufacture high-strength fasteners, pins, and symmetrical turned blanks.
- Aluminum structural rivets
- Automotive specialty fasteners
- High-speed production rates
- Burnished surface finish
Flashless Die Forging
Completely enclosed die cavities form parts without flash waste, achieving maximum material utilization and environmental efficiency.
- Zero flash scrap
- Net-shape features
- Economical high volume
- Consistent part weight
Extrusion Forging
Combines backward and forward extrusion to shape hollow cylindrical aluminum parts, housings, and deep-cavity components.
- Filter housings & cylinders
- Stepped shaft blanks
- Deep internal cavities
- Uniform wall thickness
Aluminum Forging Manufacturing Process
Precision thermal and mechanical processing from billet to finished component.
Billet Cutting & Preheat
Precision saw-cut aluminum bar stock to target slug weights. Preheat billets in multi-zone furnaces to 400°C–500°C with automated thermal monitoring.
Precision Press Forging
Transfer heated billet to lubricated forging dies. Apply controlled press tonnage to align grain flow and fill complex die cavities without cold shuts.
Trimming & Piercing
Pass forged blank through automated trimming presses to remove parting-line flash and pierce internal openings.
T6 Heat Treatment & Aging
Perform solution heat treatment in drop-bottom furnaces followed by rapid water quench and artificial precipitation aging to T6/T651 temper.
CNC Machining & Finishing
Finish machine critical features on 5-axis CNC centers. Apply anodizing, shot blasting, and 100% CMM inspection prior to packaging.
Advanced Aluminum Forging Infrastructure
Modern press lines, automated furnace controls, and metallurgical testing.
Aluminum Alloys We Forge
Extensive selection of forgeable aluminum alloy grades.
6061-T6 Aluminum
Versatile medium-to-high strength alloy with excellent corrosion resistance and weldability for structural parts.
7075-T6 Aluminum
Ultra-high strength zinc alloy (570 MPa tensile) used in aerospace structural fittings and high-stress automotive parts.
2024-T3 / T6 Aluminum
Copper-alloyed aerospace grade featuring high fatigue strength and structural toughness under cyclic loads.
6082-T6 Aluminum
High-strength structural alloy widely specified across European automotive and structural engineering industries.
5083-H116 Aluminum
Marine-grade alloy offering exceptional resistance to seawater corrosion and chemical degradation.
7050-T7451 Aluminum
Advanced aerospace alloy combining high strength with superior stress-corrosion cracking resistance.
Industries We Serve
Precision forged aluminum components for critical sectors worldwide.
Automotive Suspension & Chassis
- Control arms & steering knuckles
- Engine mounts & brackets
- Connecting rods & piston blanks
- Transmission housings
- EV battery enclosure brackets
Aerospace & Defense
- Landing gear structural brackets
- Wing spar fittings & hinges
- Avionics chassis frames
- Flight control levers
- Rocket & missile fittings
Marine & Subsea
- Outboard motor brackets
- Subsea sensor housings
- Propeller shaft couplings
- Seawater valve bodies
- Deck hardware fittings
Industrial & Robotics
- Robotic arm structural links
- Pneumatic cylinder caps
- High-pressure valve manifolds
- Textile machinery components
- Conveyor system arms
Racing & High-Performance
- Forged racing wheels & hubs
- High-RPM connecting rods
- Brake caliper bodies
- Suspension rocker arms
- Dry sump oil pan fittings
Safety & Hardware
- Climbing carabiners & D-rings
- Fall protection safety hardware
- Non-sparking industrial tools
- High-strength pipe wrenches
- Scaffolding clamps
Aluminum Forging Specifications
Quantitative manufacturing limits for custom aluminum forgings.
Component Weight
0.1 kg to 45 kg
Small to heavy forged parts
Press Capacity
300 to 3,500 Tons
High-pressure forming
Preheat Temperature
400°C to 500°C
Precise PLC control
Finished Tolerances
±0.01mm (CNC Finish)
±0.2mm (Forged Blank)
Rigorous Quality Inspection
Zero-defect quality systems ensuring structural and dimensional compliance.
Trusted Global Partner
Exporting precision aluminum forgings to 21+ countries worldwide.
Automotive
Aerospace
Marine
Defense
Robotics
Safety Gear
Electrical
Hydraulics
Aluminum Forging FAQs
Answers to common questions regarding aluminum forging alloys, tolerances, T6 heat treatment, and order quantities.
Related CNC Machining & Manufacturing Capabilities
Explore our integrated manufacturing capabilities to streamline your component sourcing.
Custom Fastener Manufacturer
ISO-certified precision manufacturing & custom component production.
Custom Investment Cast Parts
ISO-certified precision manufacturing & custom component production.
Precision Machining Services
ISO-certified precision manufacturing & custom component production.
CNC Turned Components
ISO-certified precision manufacturing & custom component production.
Need Custom Precision Aluminum Forging?
Partner with Fedele Autocore for high-strength, lightweight aluminum forged components. Our engineering team is ready to review your drawings and provide a competitive quote within 24 hours.
Have 2D/3D CAD Drawings?
Send STEP, IGES, DXF, or PDF files directly on WhatsApp for immediate evaluation & 24-hour RFQ pricing.