United States Metal Forging Market Overview,2030

The US Metal Forging Market represents a significant component of the nation’s advanced manufacturing landscape, combining technological modernization with robust industrial traditions that have shaped the evolution of forged components for a diverse array of sectors. Forging as a metalworking process has long underpinned critical infrastructure, providing the backbone for automotive, aerospace, construction, and industrial machinery applications, which rely on resilient, reliable, and intricately shaped parts to achieve high standards of performance and safety. The enduring importance of forging within the largest advanced economy is maintained through continual investments in research and development and the pursuit of innovation in material science, engineering design, and process automation. A deep-rooted ecosystem of suppliers, part makers, and original equipment manufacturers supports this sector, ensuring that forged parts conform to stringent quality and tolerance requirements demanded by both legacy and evolving industries. National objectives related to defense, energy, and transportation further drive the domestic forging sector to continually refine its capacity to produce high-precision, durable, and lightweight solutions, often adapting to new technological paradigms such as electrification, mobility, and military modernization. The US market landscape for metal forging is characterized by a concentration of established players and niche innovators, each leveraging specialized tooling, unique alloys, and flexible production strategies to meet shifting customer requirements. Environmental and regulatory factors also influence the strategic direction of the market, with increasing pressure placed on reducing energy consumption during forging, enhancing resource efficiency, and integrating cleaner production practices into standard operations.

According to the research report, ""United States Metal Forging Market Overview, 2030,"" published by Bonafide Research, the United States Metal Forging market was valued at more than USD 17.30 Billion in 2024.As industries evolve towards higher-performance standards and stricter safety regulations, metal forging remains critical due to its ability to produce components with superior strength, toughness, and dimensional accuracy compared to other manufacturing methods. Growth factors include rising investments in aerospace and defense modernization programs, the transformation of automotive manufacturing towards lightweight and electrified vehicles, and increased demand from construction and oil and gas sectors focusing on reliability and durability. The market benefits from advanced process innovations, such as precision closed-die forging, which facilitates complex geometries while minimizing material waste, alongside open-die and rolled ring forging methods tailored to large and intricate components. These process improvements have led to increased adoption in power generation industries where forged parts must withstand extreme operational conditions. Additionally, digital technologies such as Industry 4.0 integration, artificial intelligence, and smart manufacturing systems have enhanced supply chain coordination, process monitoring, and predictive maintenance, fostering operational excellence and cost reduction. The American forging industry is further supported by a strong research ecosystem encompassing universities, government laboratories, and corporate centers focused on metallurgy and forging science. Sustainability considerations are instrumental in driving growth, with companies prioritizing energy-efficient furnaces, reuse of scrap metal, and reducing carbon footprints aligned with federal environmental policies. Furthermore, government incentives encourage modernization and green technology adoption that contribute to competitive advantages in global markets.

Carbon steel remains foundational within forging operations due to its excellent strength and affordability, supporting high-volume production of structural components for automotive frames, heavy machinery, and construction equipment. Its versatility and weldability make it the preferred choice where robust yet cost-efficient solutions are necessary. Alloy steel, incorporating elements such as chromium, molybdenum, and nickel, offers enhanced strength, toughness, and resistance to wear and corrosion, making it favored for applications demanding superior mechanical integrity, such as aerospace fasteners, automotive drivetrain parts, and oil and gas infrastructure. Its adaptability to heat treatment processes further expands its suitability in performance-critical forging tasks. Stainless steel is valued in the US market for its corrosion-resistant and hygienic properties, often used in aerospace, chemical processing, and power generation components where high durability and exposure to harsh environments prevail. The industry’s approach to stainless steel forging integrates precision techniques ensuring optimal grain flow and surface quality, which are imperative for safety-critical applications. Aluminum forging commands attention for its lightweight yet durable nature, aligning with the transportation industry's drive towards fuel efficiency and emissions reduction. Forged aluminum components are prevalent in automotive bodies, aircraft structures, and lightweight machinery parts. Titanium forging benefits sectors requiring exceptional strength-to-weight ratios and corrosion resistance, most notably aerospace and defense, where its biocompatibility also opens niche applications. The market also witnesses the use of other metals such as nickel-based superalloys, copper-based alloys, and magnesium, utilized for their specialized capabilities nickel alloys in high-temperature turbine components, copper alloys in electrical and thermal conductors, and magnesium for ultralight materials in automotive and electronics.

Closed Die Forging, one of the most widely used processes, offers high precision and repeatability by shaping metal between two contoured dies under high pressure, making it ideal for complex shapes and high-volume manufacturing. This process produces parts with excellent mechanical strength due to refined grain flow, such as automotive components, aerospace fittings, and industrial gears that require tight dimensional tolerances and consistent structural integrity. Its efficiency in material usage and surface finish improvement further contributes to its extensive application. Open Die Forging, alternatively, is characterized by the deformation of metal between flat or simple-shaped dies, allowing production of larger, less complex components like shafts, rings, and discs used in heavy machinery, power generation, and structural fabrication. This process offers greater flexibility and is especially suited for low to medium volume applications where size and shape versatility are essential. The slower deformation and reheating cycles in open die forging contribute to superior internal grain structure and fatigue resistance, favorable for critical applications subjected to cyclic stresses. Rolled Ring Forging occupies a specialized niche where seamless rings with uniform mechanical properties are essential, primarily serving the aerospace, oil and gas, and bearing industries. This process involves expanding a thick-walled ring blank over a mandrel while rolling between dies, creating rings that meet stringent performance criteria such as high strength, toughness, and dimensional accuracy. Technological advancements in ring forging, including automation and computer-controlled rolling, have enhanced quality consistency and production throughput in the US market. Across these forging processes, the integration of computer-aided design and manufacturing tools accelerates die design optimization, process simulation, and quality control, minimizing defects and costly rework. Additionally, the application of advanced heating methods, such as induction and controlled atmosphere furnaces, improves energy efficiency and metallurgical outcomes.

The metal forging market in the US serves a broad spectrum of applications, each demanding unique material properties and forging techniques to deliver components that meet stringent performance and reliability standards. Automotive and transportation constitute one of the largest sectors benefiting from metal forging, where forged parts such as connecting rods, crankshafts, gears, and suspension components are essential for vehicle safety, durability, and efficiency. As the automotive industry shifts towards electrification and lightweight designs, forging technologies adapt to produce aluminum and high-strength steel components that reduce vehicle weight and improve fuel economy without compromising strength. Aerospace and defense sectors demand forged components that can withstand extreme stress, high temperatures, and corrosive environments. Components like turbine blades, landing gear, structural airframe elements, and weapon system parts require the high strength, fracture toughness, and precise dimensional control that forging processes provide. Forging also enhances component reliability and safety criticality in these sectors, which operate under stringent regulatory and certification regimes. The oil and gas industry utilizes forged parts in drill bits, valves, flanges, and pipeline components, where resistance to wear, fatigue, and corrosive substances is vital for operational integrity in harsh environments. Forging ensures the mechanical robustness of parts that support extraction, transportation, and refining processes, contributing to longer service life and reduced operational risks. Construction and agriculture industries rely on forged components such as heavy machinery gears, shafts, couplings, and structural parts that endure dynamic loads and challenging operating conditions. Forged metal parts in these sectors provide the strength and toughness required for reliable performance in infrastructure development and farming operations. Power generation, particularly industrial machinery like turbines, generators, and compressors, incorporates forged parts where durability under continuous high-stress conditions is critical. Manufacturing forged components with refined grain structures and tailored alloy compositions enhances machine efficiency, longevity, and safety.

Considered in this report
• Historic Year: 2019
• Base year: 2024
• Estimated year: 2025
• Forecast year: 2030

Aspects covered in this report
• Metal Forging Market with its value and forecast along with its segments
• Various drivers and challenges
• On-going trends and developments
• Top profiled companies
• Strategic recommendation

By Material Type
• Carbon Steel
• Alloy Steel
• Stainless Steel
• Aluminum
• Titanium
• Others Metals

By Application
• Automotive & Transportation
• Aerospace & Defense
• Oil & Gas
• Construction & Agriculture
• Power Generation (Industrial Machinery)
• Other Applications

By Process Type
• Closed Die Forging
• Open Die Forging
• Rolled Ring Forging Show more