The High Velocity Forging Hammer

This film "The High Velocity Forging Hammer" was directed by John L. Apostolou. It documents the development and demonstration of a high energy rate forging hammer, capable of delivering vastly greater impact energy than a conventional model. By substituting speed for mass, the process enables precise control of metal flow, producing complex shapes with thin and thick sections, refined grain structure, and superior strength without excessive machining or reheating. Through examples ranging from helicopter transmission gears and turbine wheels to rocket missile cases and aerospace components made from steel, nickel alloys, and titanium, the film demonstrates improved quality, reduced costs, and significant gains in fatigue life. High energy rate forging is a practical, economical, and versatile manufacturing breakthrough with major implications for space-age technology.



00:00 –Main titles. In August 1967, a high energy rate forging hammer is demonstrated. It marks a major technological advance in metal forming.
0:49 – High energy rate forging is explained as a process that substitutes velocity for mass to shape metal, a technique previously little used in industry.
1:03 – A standard drop forging hammer is converted from 10,000 ft-lb to nearly 250,000 ft-lb of impact energy by dramatically increasing ram velocity.
1:24 – Spring mounting absorbs shock and prevents vibration, allowing operation in light-manufacturing zones.
1:36 – Precision Forge Company converts the hammer under a USAF contract, with continued development supported after its acquisition by Whitica Corporation.
1:56 – The hammer is upgraded into a full production facility with furnaces, trim presses, and supporting equipment.
2:15 – A typical operation shows heated alloy steel billets forged into shape with controlled, high-energy blows.
2:34 – A hydropneumatic nitrogen system allows precise control of stroke and pressure, enabling the forging of many metals.
2:51 – Rapid energy delivery improves metal flow, fills complex dies, and produces thin and thick sections without grain enlargement.
3:18 – Improved grain structure and flow result in forgings with maximum attainable strength.
3:30 – Spiral bevel gears for military helicopter transmissions are forged with minimal machining.
3:52 – Pinions are also produced with single-blow forming and die changes, demonstrating consistent quality.
4:36 – The hammer successfully produces challenging parts such as turbine wheels, reducing costs while meeting strict specs.
5:06 – Rocket missile cases are forged with uniform wall thickness, minimizing machining and scrap.
5:31 – Difficult nickel alloys respond well to high energy rate forging, yielding stable, fine-grained parts with improved strength.
6:01 – Titanium components are forged at lower temperatures with controlled reheating, achieving superior aerospace properties.
6:28 – Special flanges show significant metallurgical improvement and guaranteed high yield strength.
6:47 – Uniform low-carbon steel parts are produced without machining, showing excellent surface quality and dimensional control.
7:17 – Spur gears are forged with grain flow following tooth profiles, eliminating cutting operations and increasing strength.
7:49 – Spiral bevel gear development promises major breakthroughs in manufacturing economy and fatigue life.
8:11 – Studies indicate most standard forging hammers could be converted economically into high velocity tools.
8:27 – Industry interest grows, and the Air Force initiates conversion of additional hammers for higher production capacity.
8:40 – The film concludes by affirming the high velocity forging hammer as a practical, versatile technology contributing significantly to the space-age era.


"Report on the high velocity forging hammer". U.S. Air Force Missile Command film, 400', color, made by John L. Apostolou. Shows forging techniques for space and missile components using high velocity forging hammers.