An American National Standard

Designation: A 521 – 96 (Reapproved 2001)

Standard Specification for

Steel, Closed-Impression Die Forgings for General Industrial
Use1
This standard is issued under the fixed designation A 521; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope Alloy, Hot-Wrought and Cold-Finished, General Require-

1.1 This specification covers untreated and heat-treated ments for2
steel, closed-impression die forgings (Note 1) for general A 322 Specification for Steel Bars, Alloy, Standard Grades2
industrial use. A 370 Test Methods and Definitions for Mechanical Testing
of Steel Products3
NOTE 1—For the definition of a forging, refer to Definition A 509. A 509 Definition of Terms Relating to Steel Forging4
1.2 The classes of forgings are as follows, the choice A 576 Specification for Steel Bars, Carbon, Hot-Wrought,
depending on design and stress or service to be imposed: Special Quality2
1.2.1 Class CA—Untreated, carbon steel forgings, A 711 Specification for Steel Forging Stock2
1.2.2 Classes CC, CC1, and CE—Annealed, normalized E 10 Test Method for Brinell Hardness of Metallic Materi-
and tempered, carbon steel forgings, als5
1.2.3 Class CF—Normalized and tempered carbon steel E 23 Test Method for Notched Bar Impact Testing of
forgings, Metallic Materials5
1.2.4 Class CF1—Double normalized and tempered carbon E 94 Guide for Radiographic Examination6
steel forgings,
1.2.5 Class CG—Quenched and tempered, or normalized, 3. Terminology
quenched and tempered carbon steel forgings, 3.1 Definitions of Terms Specific to This Standard:
1.2.6 Class AA—Annealed, normalized, or normalized and 3.1.1 annealing—the forgings shall be reheated to a tem-
tempered alloy steel forgings, perature which produces an austenitic structure and then cooled
1.2.7 Classes AB and AC—Normalized and tempered alloy slowly. A furnace charge thus treated is termed an annealing
steel forgings, and charge.
1.2.8 Classes AD, AE, AF, AG, and AH—Normalized, 3.1.2 cooling prior to heat treatment—after forging and
quenched, and tempered alloy steel forgings. before reheating for heat treatment, the forgings shall be cooled
to provide substantially complete transformation of austenite.
NOTE 2—The appendix tables list recommended tolerances for a
number of materials other than those covered by the above classes. The 3.1.3 normalizing—the forgings shall be reheated to a
tables are for information only and the purchaser must define the condition temperature which produces an austenitic structure and then
in which he desires forgings made from materials not described above. withdrawn from the furnace and cooled in air. A furnace charge
1.3 The values stated in inch-pound units are to be regarded thus treated is termed a normalized charge.
as the standard. 3.1.4 quenching—the forgings shall be reheated to a tem-
perature which produces an austenitic structure and then
2. Referenced Documents quenched in a suitable liquid medium by spraying or immer-
2.1 ASTM Standards: sion. A group thus treated is termed a quenching charge.
A 29/A 29M Specification for Steel Bars, Carbon and 3.1.5 tempering—the forgings shall be reheated to and held
at the proper temperature, which will be below the austenitic

1 2
This specification is under the jurisdiction of ASTM Committee A01 on Steel, Annual Book of ASTM Standards, Vol 01.05.
3
Stainless Steel and Related Alloys and is the direct responsibility of Subcommittee Annual Book of ASTM Standards, Vol 01.03.
4
A01.06 on Steel Forgings and Billets. Discontinued—see 1982 Annual Book of ASTM Standards, Vol 01.05.
5
Current edition approved Sept. 10, 1996. Published July 1997. Originally Annual Book of ASTM Standards, Vol 03.01.
published as A 521–64. Last previous edition A 521–76 (1992)e1. 6
Annual Book of ASTM Standards, Vol 03.03.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

1
 A 521
transformation range, and then cooled under suitable condi- taken from the forging or from a full-size prolongation, at any
tions. A furnace charge thus treated is termed a tempering point midway between the center and surface when solid, or
charge. between the inner and outer surfaces of the wall when bored;
or turnings may be taken from the test specimen. The chemical
4. Ordering Information composition thus determined shall not vary from the require-
4.1 The purchaser shall specify in the inquiry, contract, and ments specified in Section 8 by more than the amounts
order the class of steel desired; and any exceptions, modifica- prescribed for product analysis in Specification A 711.
tions, or agreements with regard to the provisions of this
specification. 13. Tensile Properties
13.1 The material shall conform to the requirements for
5. Process
tensile properties prescribed in Table 1 when tested in accor-
5.1 The steel shall be made by any or all of the following dance with the latest issue of Test Methods and Definitions
processes: open-hearth, electric-furnace, or basic-oxygen. A 370.
6. Discard 13.2 The yield strength shall be determined by the offset
method, using an offset value of 0.2 % of the gage length, or by
6.1 Sufficient discard shall be made to secure freedom from the total extension under load method, using an extension value
piping and undue segregation. of 0.005 in./in. (0.5 %) for Classes AD and AE, 0.006 in./in.
7. Forging Manufacture (0.6 %) for Classes AF and AG, and 0.007 in./in. (0.7 %) for
Class AH.
7.1 Manufacturing practice shall be in accordance with
13.3 Tests for acceptance shall be made after final heat
accepted commercial procedures designed to produce forgings
treatment of the forgings.
free from harmful surface discontinuities, roughness, excessive
scale, fins, indications of overheating, or other injurious 14. Number of Tests
discontinuities. The manufacturer may be required to certify 14.1 One tension test shall be made for each heat of steel for
that furnaces used for all heating operations for forging and each heat treat charge. For untreated forgings (Class CA) no
heat treating are controlled to minimize scaling and decarbur- tension tests shall be made except when specified in the
ization and equipped with suitable controls. purchase order and then one tension test shall be run on each
8. Chemical Requirements heat.
14.2 If any test specimen fails because of mechanical
8.1 The steel shall conform to the requirements for chemical
reasons, such as testing equipment failure or improper speci-
composition listed in Table 1 on alloy steel bars in Specifica-
men preparation, it may be discarded and another specimen
tion A 322 or in Table 1 on carbon steel bars in Specification A
taken.
576. Other limits may be specified for carbon steels using the
14.3 For the purpose of tests of heat-treated forgings, the
ranges and limits in Table 2 of Specification A 576 or for alloy
necessary extra forgings shall be provided. When it is imprac-
steels in Table 4 of A 29/A 29M.
ticable to provide extra forgings for test purposes, test bars may
8.2 The limits of elements other than those listed above may
be made from the billet or bar, provided they are given
be agreed upon by the manufacturer and purchaser.
approximately the same reduction and heat treatment as the
9. Dimensional Tolerances forgings and also represent the maximum cross section of the
9.1 Tolerances for impression die forgings (Appendix X1) forging.
shall apply. 15. Retests
10. Finish 15.1 If the results of the mechanical tests of any test lot do
10.1 The forgings shall be free of injurious discontinuities. not conform to the requirements specified, the manufacturer
may reheat treat such lot, but not more than three additional
11. Heat Analysis times unless authorized by the purchaser, and retests shall be
11.1 An analysis of each heat of steel shall be made by the made in accordance with Section 14.
manufacturer to determine the percentages of carbon, manga- 15.2 If the percentage of elongation of any tension test
nese, phosphorus, sulfur, and silicon; also the alloying ele- specimen is less than that specified in Table 1 and any part of
ments agreed on in accordance with Section8. This analysis the fracture is outside of the middle half of the gage length, a
shall be made from a test ingot taken during the pouring of the retest shall be allowed.
heat. The chemical composition thus determined shall be 15.3 If a test specimen fails to meet the specified mechani-
reported to the purchaser or his representative, and the percent- cal property requirements due to a discontinuity other than a
ages of phosphorus and sulfur, and also the alloying elements rupture, crack, or flake, a retest shall be allowed.
shall conform to the requirements specified and agreed upon in
Section 8. 16. Test Specimen
16.1 Location, size, and number of test specimens shall be
12. Product Analysis specified by the purchaser. Unless otherwise stated in the
12.1 An analysis may be made by the purchaser from a contract or purchase order, test bars may be separately forged
forging representing each heat. Drillings for analysis may be or swaged from the same bars, billets, or blooms used in

2
 A 521
TABLE 1 Tensile Requirements
Class Solid Diameter or Thickness, Bored Wall Thickness in. (mm) Tensile Yield Strength, Elongation Reduction
in. (mm) Strength, min, ksi in 2 in. or of Area,
min, ksi (MPa) 50 mm, min, %
Over Not Over Over Not Over (MPa) min, %
AA (Annealed, normalized, or ... 12 (305) ... ... 80 (550) 50 (345) 24 40
normalized, and tempered) 12 (305) 20 (508) ... ... 80 (550) 50 (345) 22 38
AB (Normalized and tempered) ... 7 (178) ... 4 (102) 80 (550) 55 (380) 26 52
7 (178) 20 (508) 4 (102) 71⁄2 (191) 80(550) 55(380) 24 50
AC (Normalized and tempered) ... 7 (178) ... 4 (102) 90 (620) 60 (415) 22 44
7 (178) 20 (508) 4 (102) 71⁄2 (191) 90 (620) 58 (400) 21 42
AD (Normalized, quenched, and ... 7 (178) ... 31⁄2 (89) 96 (655) 70 (485) 20 50
tempered) 7 (178) 10 (254) 1⁄2 (89) 5 (127) 90 (620) 65 (450) 20 50
AE (Normalized, quenched, and ... 7 (178) .... 31⁄2 (89) 105 (725) 80 (550) 20 50
tempered) 7 (178) 10 (254) 31⁄2 (89) 5 (127) 100 (690) 75 (520) 19 50
10 (254) 20 (508) 5 (127) 8 (203) 95 (655) 70 (485) 19 50
AF (Normalized, quenched, and ... 4 (102) ... 2 (51) 125 (860) 105 (725) 16 50
tempered) 4 (102) 7 (178) 2 (51) 31⁄2 (89) 115 (795) 96 (655) 16 45
7 (178) 10 (254) 31⁄2 (89) 5 (127) 110 (760) 85 (585) 16 45
AG (Normalized, quenched, and ... 4 (102) ... 2 (51) 145 (1000) 120 (830) 15 45

tempered) 4 (102) 7 (178) 2 (51) 31⁄2 (89) 140 (965) 115 (795) 14 40
7 (178) 10 (254) 31⁄2 (89) 5 (127) 135 (930) 110 (760) 13 40
AH (Normalized, quenched, and ... 4 (102) ... 2 (51) 170 (1175) 140 (965) 13 40
tempered) 4 (102) 7 (178) 2 (51) 31⁄2 (89) 165 (1140) 135 (930) 12 35
7 (178) 10 (254) 31⁄2 (89) 5 (127) 160 (1105) 130 (895) 11 35
(No Physical Requirements except as covered by 13.1.)
CA (Untreated) ... ... ... ... ... ... ... ...
CC (Annealed, normalized, or ... 12 (305) ... ... 60 (415) 30 (205) 25 36
normalized, and tempered) 12 (305) ... ... ... 60 (415) 30 (205) 24 36
CC1 (Annealed, normalized, or ... 12 (305) ... ... 66 (455) 33 (230) 23 36
normalized and tempered) 12 (305) 20 (508) ... ... 66 (455) 33 (230) 22 34
CE (Annealed, normalized, or ... 8 (203) ... ... 75 (520) 37 (290) 24 40
normalized and tempered) 8 (203) 12 (305) ... ... 75 (520) 37 (290) 22 35
12 (305) 20 (508) ... ... 75 (520) 37 (290) 20 32
20 (508) ... ... ... 75 (520) 37 (290) 19 30
CF (Normalized and tempered) ... 8 (203) ... ... 80 (550) 40 (275) 22 36
8 (203) 12 (305) ... ... 80 (550) 40 (275) 21 33
12 (305) 20 (508) ... ... 80 (550) 40 (275) 20 31
CF1 (Double normalized and tempered) ... 8 (203) ... ... 85 (585) 44 (305) 25 40
8 (203) 12 (305) ... ... 83 (570) 43 (295) 23 37
12 (305) 20 (508) ... ... 83 (570) 43 (295) 22 35
CG (Quenched, and tempered or ... 4 (102) ... 2 (51) 90 (620) 55 (380) 20 39
normalized, quenched and tempered) 8 (203) 7 (178) 2 (51) 31⁄2 (89) 85 (585) 50 (345) 20 39
7 (178) 10 (254) 31⁄2 (89) 5 (127) 85 (585) 50 (345) 19 37
... ... 5 (127) 10 (254) 82 (565) 48 (330) 19 36

manufacture of the forgings. The percentage reduction given 18. Marking

the forged tests bars shall not be greater than the minimum 18.1 Marking of forgings shall be specified by the pur-
amount of reduction given the forging itself. The test bars shall chaser.
be heat treated with the forgings they represent. The manufac-
turer may elect to submit an extra forging in lieu of forged test 19. Inspection
bars. 19.1 Unless otherwise specified, the inspector representing
16.2 Unless otherwise specified, the axis of the specimen the purchaser shall have entry, at all times while work on the
shall be located at any point midway between the center and contract of the purchaser is being performed, to those parts of
the surface of solid forgings or at any point midway between the manufacturer’s plant that concern the manufacture of the
the inner and outer surfaces of the wall of hollow forgings, and material ordered. The manufacturer shall afford the inspector,
shall be parallel to the direction of maximum metal flow. without charge, all reasonable facilities to satisfy him that the
16.3 The specimens shall be machined to the form and material is being furnished in accordance with this specifica-
dimensions shown in Test Methods and Definitions A 370 for tion. All tests (except product analysis) and inspection shall be
the standard or subsize round tension test specimens. made at the place of manufacture prior to shipment, unless
otherwise specified, and shall be conducted so as not to
17. Cleaning interfere unnecessarily with the operation of the plant.
17.1 The forgings shall be furnished in a scale-free condi-
tion. Unless otherwise specified, the manufacturer may clean 20. Rejection
by acid pickling, grit blasting, sand blasting, or other abrasive 20.1 Any rejection based on tests made in accordance with
method. Section 10 shall be reported to the manufacturer within 60 days

3
 A 521
from the receipt of samples by the purchaser. and inspected in accordance with the specified provisions of
20.2 Material that shows injurious discontinuities subse- the specification. Each certification so furnished shall be signed
quent to its acceptance at the manufacturer’s plant will be by an authorized agent of the supplier or manufacturer.
rejected, and the manufacturer shall be notified.
22. Repair of Forgings
21. Certification
21.1 A certification shall be made the basis of acceptance of 22.1 Forgings shall not be weld repaired. Grinding to
the material. This shall consist of a copy of the manufacturer’s remove surface discontinuities will be permitted unless other-
test report stating that the material has been sampled, tested, wise specified by the purchaser.

SUPPLEMENTARY REQUIREMENTS

One or more of the following supplementary requirements shall apply only when specified by the
purchaser in the inquiry, contract, and order. Details of these supplementary requirements shall be
specified by purchaser.

S1. Magnetic Particle Test number of tests, and standards for acceptance shall be specified
S1.1 When magnetic particle inspection of forgings is by the purchaser. Reference shall be made to Test Method E 23.
required, the specific method, the areas to be inspected, and the
standards of acceptability shall be specified by purchaser. S5. Ultrasonic Tests

S2. Grain Flow S5.1 When ultrasonic tests are required, details as to proce-
dure and standards shall be specified by the purchaser.
S2.1 When a specific pattern of grain flow is required by the
purchaser, a sample forging shall be sectioned as specified. The
S6. Radiographic Tests
section shall be ground and subjected to acid etching, using the
type of acid, temperature and time of etching agreed upon to S6.1 When radiographic tests are required, the number of
reveal flow lines. The section may be preserved using a coating tests, location, and ASTM standards of acceptance shall be
of mineral oil or clear lacquer. specified by the purchaser. Reference shall be made to Practice
E 94.
S3. Microscopical Test
S3.1 When microscopical examination is specified, the steel S7. Brinell Hardness
shall be inspected by utilizing samples cut from the undistorted
portion of tension test specimens. Requirements for number of S7.1 When hardness is required, Brinell hardness tests of
microscopical tests, grain size, cleanliness, or microstructure sample forgings from each furnace charge of heat treated
shall be specified by purchaser. forgings shall be conducted. Number of samples per charge
shall be specified by the purchaser. Reference should be made
S4. Impact Test to the latest issue of Test Method E 10.
S4.1 When impact tests are required, the type of specimen,

APPENDIXES

(Nonmandatory Information)

X1. FORGINGS PRODUCED ON HAMMERS AND PRESSES

X1.1 Units of Measure TABLE X1.1 Units of Measure

Dimensions, ft (m) Units of Measure to the
X1.1.1 Where direct tolerances are not provided, use Table Closest
X1.1 in converting to fractional units of measure after making Over Under

computations. ... 2 (0.61) ⁄

1 32 in.
2 (0.61) 5 (1.52) ⁄
1 16 in.
5 (1.52) 10 (3.05) 1⁄8 in.

X1.2 Length and Width Tolerances 10 (3.05) ... 1⁄4 in.

X1.2.1 Length and width tolerances represent variations in

dimensions measured parallel to the fundamental parting line
of the dies. Normally, they are combined with tolerances for X1.2.1.1 Tolerance—The length and width tolerance is
die wear. 60.003 in./in. and applies to all dimensions of length and

4
 A 521
width including diameters. This tolerance includes allowance wear, and pertain to variations in dimensions crossing the
for shrinkage, die sinking, and die polishing variations. fundamental parting line.
X1.2.1.2 Units of Measure—Length and width tolerances, X1.4.1.1 Tolerance—Die closure tolerances on forgings
normally combined with tolerances for die wear, are expressed having no portions extending more than 6 in. (152 mm) from
as fractions of an inch, in units of 1⁄32 in. or greater as shown the parting line are based on the projected area of the forging
in Table X1.1. Decimals used in computing tolerances are at the trim line—not including flash, but including all areas to
totaled, rounded off to two places after the decimal point, then be subsequently punched out. Except as explained in the
converted to the next higher fractional unit of measure. following paragraph, they are applied as plus tolerances only
and are applicable to the thickness of the forging at all sections.
X1.3 Die Wear Tolerances (See Table X1.3.)
X1.3.1 Die wear varies according to the material forged and X1.4.1.2 Tolerances on extremities of forgings extending
the shape of the forging. Consequently, die wear tolerances for perpendicularly more than 6 in. from the parting line include
various materials are applied in addition to length and width the die closure tolerance, and, in addition, a length tolerance of
tolerances on dimensions pertaining to forged surfaces only. 60.003 in./in. This tolerance is added to that derived from
Die wear tolerances do not apply on center-to-center dimen- Table X1.3, but applies only to such extremities.
sions. X1.4.1.3 Units of Measure—Die closure tolerances are
X1.3.1.1 Tolerance—Die wear tolerances for all external expressed as fractions of an inch in units of 1⁄32 in. or greater.
length, width, and diameter dimensions are computed by When decimals are used in computing tolerances, they are
multiplying the greatest external length or outside diameter rounded off to two places after the decimal point, then
(measured parallel to the fundamental parting line of the dies) converted to the next higher fractional unit of measure.
by the appropriate factor in Table X1.2 and are then combined
with plus values of length and width tolerances. Die wear X1.5 Match Tolerances
tolerances on external dimensions are expressed as plus values X1.5.1 Match tolerances relate to displacement of a point in
only. one die half from the corresponding point in the opposite die
X1.3.1.2 Die wear tolerances for all internal length, width half in any direction parallel to the fundamental parting line of
and diameter dimensions are also computed by multiplying the the dies. Match tolerances are applied separately and indepen-
greatest external length or outside diameter (measured parallel dently of all other tolerances. Where possible, measurements
to the fundamental parting line of the dies) by the appropriate are made at areas of the forging unaffected by wearing of the
factor in Table X1.2, but are then combined with the minus dies.
values of length and width tolerances. Die wear tolerances on X1.5.1.1 Tolerance—Match tolerances are based on weight
internal dimensions are expressed as minus values only. of the forging after trimming and are expressed as fractions of
X1.3.1.3 Allowances for die wear occurring on dimensions an inch according to Table X1.4.
measured perpendicular to the fundamental parting line of the X1.5.1.2 Measuring for Match Tolerances— In cases where
dies are included in die closure tolerances. measurements for determining match tolerances must be made
X1.3.1.4 Die wear tolerances, per surface, on both external from surfaces of the forging where uneven wearing of the dies
and internal dimensions are one half the computed amount. has caused surplus stock, accuracy depends on making the
X1.3.1.5 Units of Measure—Die wear tolerances combined proper allowances for these wear-caused surpluses, and elimi-
with length and width tolerances are expressed as fractions of nating their influence from the computation.
an inch in units of 1⁄32 in. or greater as shown in Table X1.1. X1.5.1.3 Units of Measure—Match tolerances are measured
Decimals used in computing tolerances are totaled, rounded off in units of 1⁄64 in. or greater.
to two places after the decimal point, then converted to the next
higher fractional unit of measure. X1.6 Flash Extension Tolerances
X1.6.1 Flash extension tolerances are based on the weight
X1.4 Die Closure Tolerances of the forging after trimming and relate to the amounts of flash
X1.4.1 Die closure tolerances relate to variations in thick- extension. Flash is measured from the body of the forging to
ness of forgings as affected by the closing of the dies and die the trimmed edge of the flash.
X1.6.2 Tolerance—Flash extension tolerances are ex-
TABLE X1.2 Die Wear Tolerances pressed in fractions of an inch according to Table X1.5.
Materials Factor (per inch)
Carbon 0.004 X1.7 Straightness Tolerances
Low Alloy 0.005 X1.7.1 Straightness tolerances relate to deviations of sur-
400 Series Stainless 0.006
300 Series Stainless 0.007 faces and centerlines from the specified contour as caused
Super Alloy 0.008 primarily by manipulation of the piece in post-forging pro-
Titanium 0.009 cesses and, in addition, by the effects of cooling from the
Refractory Material 0.012
2014 Aluminum 0.004 forging operation, both of which may produce slight and
7075 Aluminum 0.007 gradual variations in straightness.
Magnesium 0.006 X1.7.2 Since the general shape of the forging determines the
Brass 0.002
Copper 0.002 effect of cooling and post-forging manipulation on straightness,
four classes of shape have been selected as guides in choosing

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 A 521
TABLE X1.3 Die Closure Tolerances

NOTE 1—Tabulated figures are plus values only, expressed in inches.

Materials Area at the Trim Line Flash not included, expressed in in.2(cm2)
10 (65) and un- Over 10 to 30 Over 30 to 50 Over 50 to 100 Over 100 to 500 Over 500 to 1000 Over 1000
der (65 to 194), (194 to 323), (323 to 645), (645 to 3225), (3225 to 6450), (6450)
incl incl incl incl incl
Carbon, low alloys ⁄
1 32 ⁄
1 16 ⁄
3 32 ⁄
18 ⁄
5 32 ⁄
3 16 ⁄
14

400 series stainless ⁄

1 32 ⁄
1 16 ⁄
3 32 ⁄
18 ⁄
3 16 ⁄
14 ⁄
5 16

300 series stainless 1⁄16 3⁄32 1⁄8 5⁄32 3⁄16 1⁄4 5⁄16

Super alloys, titanium 1⁄16 3⁄32 1⁄8 3⁄16 1⁄4 5⁄16 3⁄8

Aluminum, magnesium 1⁄32 1⁄32 1⁄16 3⁄32 1⁄8 3⁄16 1⁄4

Refractory alloys 3⁄32 1⁄8 5⁄32 3⁄16 1⁄4 5⁄16 3⁄8

TABLE X1.4 Match Tolerances

NOTE 1— Tabulated figures are amounts of displacement, expressed in inches, of a point in one die-half from the corresponding point in the opposite
die-half in any direction parallel to the parting line of the dies.
Materials Weights of Forgings After Trimming, lb (kg)
Less than 2 Over 2 to 5 Over 5 to Over 25 to Over 50 to Over 100 to Over 200 to Over 500 to Over 1000
(0.91) (0.91 to 25 (2.3 to 50 (11.3 100 (22.7 200 (45.4 500 (90.6 1000 (226.5 (453.0)
2.3), incl 11.3), incl to 22.7), to 45.4), to 90.6), to 226.5), to 453.0),
incl incl incl incl incl
Carbon, low alloys customarily negoti- ⁄
1 64 ⁄
1 32 ⁄
3 64 ⁄
1 16 ⁄
3 32 ⁄
18 ⁄
5 32 ⁄
3 16

Stainless steels ated with pur- ⁄

1 32 ⁄
3 64 ⁄
1 16 ⁄
3 32 ⁄
18 ⁄
5 32 ⁄
3 16 ⁄
14

Super alloys, titanium chaser 1⁄32 3⁄64 1⁄16 3⁄32 1⁄8 5⁄32 3⁄16 1⁄4

Aluminum, magnesium 1⁄64 1⁄32 3⁄64 1⁄16 3⁄32 1⁄8 5⁄32 3⁄16

Refractory alloys 1⁄16 3⁄32 1⁄8 5⁄32 3⁄16 1⁄4 5⁄16 3⁄8

TABLE X1.5 Flash Extension Tolerance

NOTE 1—Tabulated figures are ranges of flash extension, expressed in inches.
Weights of Forgings After Trimming, Materials
lb (kg)
Carbon & Low Alloy Stainless Super Alloys and Aluminum & Refractory Alloy
Titanium Magnesium
10 (4.5) and under 0 to 1⁄32 0 to 1⁄16 0 to 1⁄16 0 to 1⁄32 0 to 1⁄8
Over 10 to 25 (4.5 to 11.3), incl 0 to 1⁄16 0 to 3⁄32 0 to 3⁄32 0 to 1⁄16 0 to 3⁄16
Over 25 to 50 (11.3 to 22.7), incl 0 to 3⁄32 0 to 1⁄8 0 to 1⁄8 0 to 3⁄32 0 to 1⁄4
Over 50 to 100 (22.7 to 45.4), incl 0 to 1⁄8 0 to 3⁄16 0 to 3⁄6 0 to 1⁄8 0 to 5⁄16
Over 10 to 200 (45.4 to 90.6), incl 0 to 3⁄16 0 to 1⁄4 0 to 1⁄4 0 to 3⁄16 0 to 3⁄8
Over 200 to 500 (90.6 to 226.5), incl 0 to 1⁄4 0 to 5⁄16 0 to 5⁄16 0 to 1⁄4 0 to 1⁄2
Over 500 to 1000 (226.5 to 453.0), incl 0 to 5⁄16 0 to 3⁄8 0 to 3⁄8 0 to 5⁄16 0 to 5⁄8
Over 1000 (453.0) 0 to 3⁄8 0 to 1⁄2 0 to 1⁄2 0 to 3⁄8 0 to 3⁄4

appropriate straightness tolerances. Agreement between pur- pressed as fractions of an inch in units of 1⁄32 in. or greater, as
chaser and forging engineer on tolerances and inspection shown in Table X1.1. Decimals used in computing tolerances
methods may be desirable where the forging is not easily are rounded off to two places after the decimal point, then
classified according to shape and may be subject to a combi- converted to the next higher fractional unit of measure.
nation of straightness tolerances. Straightness tolerances are X1.7.5 Tolerances and Applications (Table X1.6):
applied independently of, and in addition to, all other toler- X1.7.5.1 Class A Shapes (Elongated—Long in relation to
ances. width and height) Tolerance: 0.003 in./in. of the greatest
X1.7.3 It is contemplated that, at times, straightening op- dimension.
erations may be required in order to achieve the tolerances X1.7.5.2 Class B Shapes (Flat, Relatively Thin)
indicated in the following text. These tolerances are not Tolerance—Straightness tolerance for Class B shapes as shown
intended to apply to refractory alloys, high-density alloys, in Table X1.7 below.
titanium, and some stainless steels. Straightness tolerances for X1.7.5.3 Class C Shapes (Thin, Flat Shapes with Appre-
forgings of such materials are best determined on the basis of ciable Protrusion at Right Angles to the Parting Line)
each individual forging design, since the configuration substan- Tolerance—Straightness tolerance on the flat disc portion of
tially influences the tendency of a forging to deviate from the Class C shapes is computed first. It is considered separately
specified contour. Straightness tolerances for these special from the tolerance on the protruding portion and is determined
forgings are commonly agreed upon by buyer and seller in in an identical manner as for Class B shapes using Table X1.7.
advance of production. Straightness tolerance on protuberance is 0.003 in./in. of
X1.7.4 Units of Measure—Straightness tolerances are ex- length.

6
 A 521
TABLE X1.6 Classes of Shapes

NOTE 1—For use in selecting appropriate Straightness Tolerances.

Class Shape of Forging Examples
A Elongated—Length dimensions great in relation to width and height long connecting rods, shafts, levers, etc.
B Flat, relatively thin disc, plates, etc.
C Flat, relatively thin, with appreciable protrusion at right angles to the wear plates, crawler track shoes, disc with hub, etc.
parting line
D Massive block-type forgings with neither length, nor width, nor thick- hydraulic pump bodies, high pressure steam chests, etc
ness being predominant

TABLE X1.7 Straightness Tolerances, Class B Shapes

Materials Area at the Trim Line, expressed in in.2(cm2) Flash not included
10 (65) Over 10 to 30 Over 30 to 50 Over 50 to 100 Over 100 to 500 Over 500 to Over 1000
and under (65 to 194), (194 to 323), (323 to 645), (645 to 3225), 1000 (3225 to (6450)
incl incl incl incl 6450), incl
Carbon, low alloy ⁄
1 32 ⁄
1 16 ⁄
3 32 ⁄
18 ⁄
5 32 ⁄
3 16 ⁄
14

400 series stainless ⁄

1 32 ⁄
1 16 ⁄
3 32 ⁄
18 ⁄
3 16 ⁄
14 ⁄
5 16

300 series stainless 1⁄16 3⁄32 1⁄8 5⁄32 3⁄16 1⁄4 5⁄16

Aluminum, magnesium 1⁄32 1⁄32 1⁄16 3⁄32 1⁄8 3⁄16 1⁄4

X1.7.5.4 Class D Shapes (Massive, Block-type Forgings) X1.9.1.1 Tolerance—Draft angle tolerances are +2° and −1°
Tolerance—Since departures from the specified configuration on all draft angles, unless modified by prior agreement between
are seldom caused by subsequent handling, straightness toler- buyer and seller.
ances are not provided. Where tolerances are desired, agree-
ment between purchaser and forging engineer is normally X1.10 Finish Allowances for Machining
reached before production proceeds.
X1.10.1 Finish allowance refers to the amount of material
X1.8 Surface Tolerances that is to be machined from the forging to obtain the finished
X1.8.1 Surface tolerances relate to depth of dressouts and part. Forging dimensions are commonly analyzed indepen-
scale pits on the forging, based on purchaser’s specification or dently, with consideration given to all applicable tolerances, in
drawing. making certain that a minimum desired clean-up exists after the
X1.8.1.1 Tolerances and Conditions—Localized dressouts forging is completed. (See Table X1.8.)
or scale pits are commonly allowed on surfaces to be finish
machined unless purchaser’s specification or drawing states
otherwise. Where purchaser specifies stock for machining,
dressouts or scale pits are commonly permitted to within 1⁄16 in.
(1.59 mm) of the finished surface or to within one-half of the
stock allowance, whichever is smaller.
X1.8.1.2 Where surfaces of forgings are intended for use in TABLE X1.8 Finish Allowances
“as forged” condition, dressouts or scale pits are commonly Greatest Dimension Minimum Finish Stock
permitted on these surfaces to a depth equal to 1⁄2 of the die Over, in. (mm) But Not Over,
per Surface
closure tolerance. in. (mm)
... 8 (203) ⁄
1 16
X1.9 Draft Angle Tolerances 8 (203) 16 (406) ⁄
3 32

X1.9.1 Draft angle tolerances apply to all draft angles, relate 16 (406) 24 (610) ⁄
18

24 (610) 36 (914) 5⁄32

to variation from draft angle specifications, and are commonly 36 (914) ... 3⁄16

measured as an addition to tolerances for die wear.

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 A 521

X2. FORGINGS PRODUCED ON FORGING MACHINES (UPSETTERS)

X2.1 Length Tolerances TABLE X2.2 Flange Tolerances

X2.1.1 Length tolerances relate to variations in dimensions NOTE 1—Based on diameters of flange (or flanges) formed.
measured parallel to the axis of the stock and apply to all Diameters Tolerances
intermediate and over-all dimensions of length except flange Over, But Not Over, Plus, MinusA
thickness dimensions and internal length (gap) dimensions in. (mm) in. (mm) in. (mm)
between flanges (see X2.2). Length tolerances include allow- ... 7 (178) ⁄
1 16 (1.59) ...
ances for die wear, shrinkage, die sinking and die polishing 7 (178) ... ⁄
3 32 (2.38) ...
variations. A
Determined individually as defined in X2.2.
X2.1.2 Tolerance—Length tolerances are plus values only,
expressed in fractions of an inch according to Table X2.1. tolerances. Tolerance provisions for shear-cut ends and slight
irregularities in diameter on the unforged stem caused by grip
X2.2 Flange Tolerances dies are commonly determined by special agreement between
X2.2.1 Flange tolerances relate to variations in flange thick- buyer and seller.
ness measured parallel to the axis of the stock. When more than X2.3.4 These tolerances apply only to forgings with circular
one flange is formed, these tolerances also apply to the shapes. Tolerances for non-circular forgings are customarily
dimension (gap) between flanges. Flange tolerances are applied determined by special agreement between buyer and seller in
separately and independently of other tolerances. advance of production.
X2.2.1.1 Tolerance—Tolerances for flange thickness and X2.3.4.1 Tolerance—Tolerances for all external forged di-
dimensions (gaps) between flanges are such that the effect is to ameters are expressed as plus tolerances only, according to
add stock on both internal and external dimensions. The Table X2.3.
amount of flange tolerance is dependent on the flange diameter X2.3.4.2 Tolerances for internal diameters of holes formed
(see Table X2.2). by the heading tool are commonly +0 in.; −1⁄16 in.
X2.2.1.2 When two flanges are formed, the tolerance on the
dimension (gap) between them is a minus tolerance only, with X2.4 Match Tolerances
a value identical to the thickness tolerance for the flange X2.4.1 Match tolerances relate to the amount of die dis-
nearest the unforged stem. placement in a direction parallel to the parting line of the grip
X2.2.1.3 Flange tolerances are shown in Table X2.2. dies. These tolerances are applied independently of, and in
addition to, all other tolerances.
X2.3 Diameter Tolerances X2.4.2 Tolerance—Match tolerances are expressed as frac-
X2.3.1 Diameter tolerances relate to variation in dimensions tions of an inch in units of 1⁄64 in. or greater, according to Table
measured perpendicularly to the axis of the stock, and are X2.4. They are based on the weight of the forging exclusive of
applied separately for each of a forging’s diameters and only to the weight of the unforged stem. The weight of the stem is
those diameters formed in the heading tool or dies. deducted from the weight of the forging before Table X2.4 is
X2.3.2 Diameter tolerances are commonly applied and mea- used.
sured in a plane other than that described by the parting line of
the forging. X2.5 Concentricity Tolerances
X2.3.3 Permissible variations in diameter on unforged stem X2.5.1 Concentricity tolerances apply to contours formed
portions of the forging are commonly governed by steel mill by the heading tool and relate to variations of the axis of the
contour from the axis of the stock. This tolerance is commonly
TABLE X2.1 Length Tolerances applied only to contours of a depth not less than one diameter.
NOTE 1—Tabulated figures are plus values only and apply to overall Concentricity tolerances are applied independently of, and in
and intermediate dimensions of length, except flange thickness and gap addition to, match tolerances.
dimensions. X2.5.1.1 Tolerance—Concentricity tolerances are ex-
Length Dimensions Tolerances pressed in fractions of an inch as total indicator readings (TIR),
Over, But Not Over, Intermediate Over-All according to Table X2.5.
in. (mm) in. (mm) Length, Length,
in. (mm) in. (mm) X2.6 Straightness Tolerances
... 3 ⁄ (79)
18 ⁄ (0.79)
1 32 ⁄ (1.58)
1 16
X2.6.1 Straightness tolerances relate to deviations of the
31⁄8 (79) 61⁄4 (159) ⁄ (1.58)
1 16 3⁄32 (2.38)

61⁄4 (159) 95⁄16 (236) 3⁄32 (2.38) 1⁄8 (3.18)

TABLE X2.3 Tolerances on Forged Diameters
95⁄16 (236) 121⁄2 (318) 1⁄8 (3.18) 1⁄8 (3.18)

121⁄2 (318) 155⁄8 (397) 5⁄32 (3.97) 5⁄32 (3.97) Diameters Tolerances
155⁄8 (397) 183⁄4 (476) 3⁄16 (4.76) 3⁄16 (4.76)
Over, But Not Over, Plus, Minus
183⁄4 (476) 217⁄8 (557) 7⁄32 (5.56) 7⁄32 (5.56)
in. (mm) in. (mm) in. (mm)
217⁄8 (557) 25 (635) 1⁄4 (6.35) 1⁄4 (6.35)

25 (635) ... Commonly determined by special agree- ... 2 (51) ⁄ (0.79)

1 32 ...
ment between buyer and seller in ad- 2 (51) 7 (178) ⁄ (1.59)
1 16 ...
vance of production 7 (178) ... 3⁄32 (2.38) ...

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TABLE X2.4 Match Tolerances

NOTE 1—Tabulated figures are amounts of die displacement in a direction parallel to the parting line of the grip dies, expressed in inches.
Materials Weights of Forgings, lb (kg)
10 (4.54) Over 10 to 25 Over 25 to 50 Over 50 to 100 Over 100 to 200 Over 200 to 500
and under (4.54 to 11.3), (11.3 to 22.7), (22.7 to 45.4), (45.4 to 90.6), (90.6 to 226.5),
incl incl incl incl incl
Carbon and low alloy ⁄
1 64 ⁄
1 32 ⁄
3 64 ⁄
1 16 ⁄
3 32 ⁄
18

Stainless steels ⁄
1 32 ⁄
3 64 ⁄
1 16 ⁄
3 32 ⁄
18 ⁄
5 32

Super alloys and titanium 1⁄32 3⁄64 1⁄16 3⁄32 1⁄8 5⁄32

Aluminum and magnesium 1⁄64 1⁄32 3⁄64 1⁄16 3⁄32 1⁄8

Refractory alloys 1⁄16 3⁄32 1⁄8 5⁄32 3⁄16 1⁄4

TABLE X2.5 Concentricity Tolerances on Holes affected by subsequent removal of draft, in which case the
Depth of Hole Total Indicator minus tolerance is commonly modified to allow a square corner
Reading to be formed.
Over, But Not Over,
(Tolerance)
in. (mm) in. (mm)
X2.9 Surface Tolerances
... 8 (203) ⁄ TIR
18

8 (203) 12 (305) ⁄ TIR

5 32 X2.9.1 Surface tolerances relate to depth of dressouts and
12 (305) ... 3⁄16 TIR
scale pits on the forging, based on purchaser’s specification or
drawing.
X2.9.1.1 Tolerances and Conditions—Localized dressouts
or scale pits are commonly allowed on surfaces to be finish
centerline of the stem and body of the forging from the true machined unless purchaser’s specification or drawing states
centerline as caused by manipulation of the piece after forging, otherwise. Where purchaser specifies stock for machining,
and by the effects of cooling from the forging operation—both dressouts or scale pits are commonly permitted to within 1⁄16 in.
of which may produce slight and gradual variations in straight- (1.59 mm) of the finished surface or to within one-half of the
ness. stock allowance, whichever is smaller.
X2.6.1.1 Tolerance—Straightness tolerances on the original X2.9.1.2 Where surfaces of forgings are intended for use in
bar stock as provided by the material suppliers commonly “as forged” condition, dressouts or scale pits are commonly
apply. permitted on these surfaces to a depth equal to 1⁄2 of the die
closure tolerance.
X2.7 Draft Angle Tolerances
X2.10 Finish Allowances for Machining
X2.7.1 When draft angles are required on a forging, the size
of the angles is generally dependent on the contour of the X2.10.1 Finish allowance refers to the amount of material
forging and is therefore commonly determined by agreement that is to be machined from the forging to obtain the finished
between buyer and seller. part. Forging dimensions are analyzed independently, with
X2.7.2 Draft angle tolerances apply to all draft angles and consideration given to all applicable tolerances, in making
relate to variation from draft angle specifications. certain that a minimum desired clean-up exists after the forging
X2.7.3 Tolerance—Draft angle tolerances are +2° and −1° is completed.
on all draft angles, unless modified by prior agreement between X2.10.1.1 Allowances—Table X2.6 indicates finish allow-
buyer and seller. ances commonly applied.
TABLE X2.6 Finish Allowances
X2.8 Radii Tolerances Greatest Diameter Minimum Finish Stock
per Surface,
X2.8.1 Radii tolerances relate to variation from purchaser’s Over, But Not Over,
in. (mm)
in. (mm) in. (mm)
radii specifications on all fillet radii and on corner radii where
draft is not subsequently removed by trimming or punching. ... 2 (51) 1 16⁄ (1.58)
2 (51) 8 (203) 3 32⁄ (2.38)
X2.8.1.1 Tolerance—Radii tolerances are plus or minus 8 (203) ... 1⁄8 (3.18)

one-half the specified radii, except where corner radii are

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 A 521

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