Aluminum forging is one of the more common components in the forging process, utilizing forging machinery to apply pressure to aluminum billets, resulting in plastic deformation and obtaining forgings with certain mechanical properties, shapes, and dimensions. Aluminum forging can eliminate defects such as casting pores during the aluminum melting process, optimizing the structure. Additionally, due to the retention of complete metal flow lines, the mechanical properties of the forgings are typically superior to castings made from the same material.
Aluminum forging typically employs either vertical or horizontal water-cooled semi-continuous casting methods. To enhance the structure and surface quality of vertical casting ingots, technologies such as electromagnetic crystallization tanks, short crystallization tanks, and hot-top casting have been developed. The water-cooled semi-continuous casting process involves introducing molten metal through a flow channel into a water-cooled crystallizer, allowing the molten metal to cool and form a solid shell. The shell is then pulled out of the crystallizer using the casting machine base, or it falls uniformly due to its own weight to form the billet.
Aluminum forging process parameters vary greatly with the alloy composition and ingot size. Generally, it is advisable to maximize casting and cooling speeds to reduce the height of the crystallization trough. The casting temperature is typically 50 to 110°C higher than the liquidus temperature of the alloy. In addition, a continuous casting and rolling process for aluminum strips has also been developed.
Different forging methods for aluminum forging have varying process flows. Among them, the hot die forging process flow is relatively long, generally following this sequence: blank cutting; forging billet heating; roller forging; die forging; trimming; drilling; straightening; intermediate inspection: checking the dimensions and surface defects of the forging. After the inspection is completed, heat treatment must be performed on the aluminum forging to eliminate forging stress and enhance metal cutting properties; cleaning work is also necessary, particularly to remove the oxidation scale from the forging surface; a subsequent correction inspection is required after the cleaning is done. In addition, aluminum forging should generally undergo appearance and hardness inspections, with critical forgings requiring further chemical composition analysis, mechanical properties, residual stress tests, and non-destructive testing.
In terms of weight, aluminum forging materials are continuously stamping during the production process, thus allowing them to withstand high pressure after forming. Additionally, forged wheels are lighter than cast wheels with the same size and strength. Generally, qualified cast wheels are about 20% heavier than forged wheels. However, a drawback of forged wheels is that their metal ductility is not as good, and they are relatively expensive, usually suitable for many vehicle types.
In summary, I personally recommend that businesses opt for aluminum forging when it comes to product forging, as it offers greater safety in the details and a superior forging experience. If businesses find the forging process too costly, they can choose wheels made from forging embryo spinning. These wheels are nearly identical in performance to forged wheels but at a lower price, providing better value for money.
