Quality policy

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The Company

Corporate vision

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Processes

Customer references

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Internacionalization

Outsourced services

Business Areas

Shipping

FORGING AND HOT STAMPING OF BRASS, COPPER AND ALUMINIUM

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  • Lead-free
    alloys

  • We can
    manage and
    manufacture
    with lead-free
    alloys

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  • Problems?
    We forge
    solutions

  • The forging process saves time, reduces costs and adds value to your products.

    The problem:

    The customer wants to minimize the raw material costs whilst also tries not to reach the production capacity limits of his machining lines.

  • Concept:

    Forging reduces significantly machining times and provides a forged product geometrically very similar to the final part design.

  • Testing:

    The design of the part is developed on the computer and then tested to avoid failures in the forging process. The forging and deburring tools are also inspected to ensure that parts can be repeatedly produced in a proper way without any failure, thereby also preventing excessive wear on the production tooling.

  • Proposal:

    The customer is provided with a cost estimate and a 3D design of the forged part, also stating the delivery date. Customers’ suggestions will be analysed and implemented into the final design.

  • Solution:

    The best forging design is chosen on the basis of the most beneficial characteristics for both the machining and forging processes.

  • Advantage:

    The forging process offers a lower total cost due to cost reduction in raw materials and machining. In this way, machining capacity will be also released, avoiding unnecessary investments required to achieve higher machining capacity.

    Savings are analysed on an individual basis depending on the geometry of the part and the material to be used in its production.

The Company

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FORBRASS S.A. is a company specialized in forging and hot stamping of non-ferrous metals, (Aluminium, brass, copper etc.) developing and adapting itself to the constant technological evolution demanded by this sector since 1993.

FORBRASS S.A. provides a specialized team, which ensures that our products meet the needs of our customers using the ISO 9001 quality standard as a point of reference.

In our factory we operate medium-tonnage presses and all the necessary additional machinery in order to offer the best possible product to each of our customers.

Business Areas

Forbrass performs services for customers
in a number of different fields,
the most representative of which are:

  • Automotive

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  • Electrical
    Appliances

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  • Taps and bathroom
    appliances

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  • Metal fittings for
    windows and doors

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  • Hydraulics
    & pneumatics

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  • Food
    industry

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  • Fire-protection
    systems

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  • Transport
    and distribution
    of water

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  • Transport
    and distribution
    of electricity

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  • Transport
    and distribution
    of gas

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Customer references

Would you like to see our customer references?
Please fill in the contact form and we will contact you as soon as possible

Processes

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Design:

The quality of our products is a result of the interaction with our customers, which enables us to find out as much as possible about the function of the product and its technical specifications. This allows us to implement a common process of “design reengineering” of the pieces we are going to produce, in order to provide the best solution for our customers.

On this basis, we establish the required processes and introduce the necessary service mechanisms to satisfy our customers’ demands, either according to our own quality standards or by adapting ourselves to those required by the customer.

Production processes:

The automation of the production process has played a vital part in guaranteeing the flexibility of our production process while maintaining a high production capacity index. Thanks to the work and supervision of our QUALITY Department, we are now in a position to guarantee an optimum level of quality in all our products.

  • Cutting: In the cutting area we have totally automated machinery with the latest technology and a high production capacity.
  • Forging: In the forging area we have four screw presses from 160TN to 560TN and two 300TN presses for both horizontal and vertical processes.
  • Deburring: In the deburring area we have five semi-automatic hydraulic presses providing a high degree of flexibility for large-scale production. We also count with a robotized automatic deburring device with computer vision, which provides productive capacity for long series.

Finishes:

  • Heat treatments. Many of our products require heat treatment in order to obtain their optimum service characteristics. Forbrass performs these treatments as part of our all-inclusive service to our customers.
  • Surface finishes. Finishes with steel shot, stainless steel shot or by vibration that guarantees a perfect finish for the end product.
  • Other finishes. We also offer other surface finishes, such as chemical paint-stripping, tin-plating, nickel-plating, silver-plating, zinc-plating, anodizing, etc.

Forging
compared to
other processes

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Forging instead
of casting

Forging
instead machined
bars/plates

The resistance of parts manufactured by casting cannot be compared to that of forged parts. The forging process provides mechanical properties far superior to those of cast parts, because the material is first pre-shaped by extrusion in bars and then shaped by hot forming in the forging process.

Given that the forging process is very stable, production costs can be lower than those of casting. Furthermore, whilst cast parts can be porous, leading to defects first discovered during machining and thus to a loss of time and money, the inner structure of forged parts is compact and the grain is redefined through heat and pressure.

The costs of casting moulds can become prohibitive, especially in low or medium volume production series. Forging tools however require comparatively low investment.

During the machining process it is important to maintain the dimensional control. The positioning and clamping of a forged part is very firm due to the stability of the material and the low variation in the forging process. Moreover, due to the stability of the material and the process, the forged parts are very stable during heat treatments, another advantage over cast parts.

Forged parts reduce machining time, produce less scrap and require less assembly time. Material is only used where necessary, thus reducing material and machining costs. In some cases it is possible to develop designs which eliminate components that are assembled in secondary operations, meaning that those components are no longer required, which avoids secondary machining and assembly operations.

The metallographic structures of the bars and plates have a grain oriented in a specific direction. However, forging redefines the metallographic structure and the distribution of the grain, improving resistance throughout the entire part. That significantly improves its metallurgical properties compared to parts machined using bars or plates.

Internacionalization

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In addition to our business in Spain, we also provide customers in other European countries such as Portugal, France, Germany etc..

Furthermore we provide customers in Asia and have the capacity to operate internationally.

Forbrass has a specialist team offering professional support for all your needs. Please contact the sales responsible in your region.

Quality policy

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FORBRASS complies with the highest quality standards in all the different processes used in its business. In this way we guarantee the quality of our performance, the traceability of the raw materials used and the adequacy of our production processes.

FORBRASS obtained the ISO 9001:2008, a quality certification confirmed by SGS, a prestigious certification company.

Outsourced services

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We have an excellent network of “partners”, who provide us with the services our customers require without forming part of the nucleus of the productive work of Forbrass. These services include machining, electrolyte plating (silver-plating, tin-plating, anodizing, etc.), assembling of systems, special packaging, and so on.

In this way we can guarantee an all-inclusive service for our customers, where FORBRASS assumes the responsibility for the requested service, and applies the highest quality standards to all stages of the process.

Shipping

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A dynamic logistics operation is a key factor in our national and international service.

Forbrass is aware of the importance of meeting agreed delivery dates, and to this end it guarantees fluid communication. This point has been included as an essential part of our Service cycle.

Corporate vision

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FORBRASS develops technologically advanced solutions for hot-forging processes in order to offer “all-inclusive solutions” to their customers using total quality and innovation as tools for developing customer relations and ensuring their loyalty.

FORBRASS is fortunate to have an expert team providing wide experience, technical skills, capacity to advise customers, with dedication and a continual quest for improvement in order to guarantee total customer satisfaction.

We forge stable relationships with our customers by providing solutions for their needs.