Aluminum Forging is also the process in which Aluminum has been shaped, usually to create Aluminum billets or finished aluminum manufactured products that have used compressive force to produce high strength pieces of aluminum. Forging is different than casting because when you cast a piece of aluminum it pours molten aluminum in a mold and allows it to cold solidify. Forging changes the grain structure of aluminum as you mechanically work/shape it creating mechanical property improvements, such as strength, fatigue resistance, and structural integrity.
Due to these benefits, many industries (including automotive, aerospace, defense, marine, railroad, and all types of industrial equipment) will continue to use aluminum forging as their preferred method of making their products, based on the lightweight, corrosion resistant properties, and excellent strength to weight ratio of aluminum.
Step-by-Step Aluminum Forging Process
The aluminum forging process starts with selecting the right type of material to forge from various available materials. Aluminium alloys are typically forged from aluminium alloy 6061 or aluminium alloy 6082, 7075 and 2014. The alloys were created with many desirable properties such as strength, resistance to corrosion, and applications for use. The forgings are then formed as strand or what we will call billets.
Each billet is cut to the required size depending on each component's specifications and the die cavity's volume. Billets are then heated in a controlled oven or furnace, usually between 350–500°C, to increase the plasticity of the material while also reducing the risk of cracking during deformation of the material. Forging dies will also be preheated and applied with a lubricating agent or some type of lubricant to create a low coefficient of friction between the forging dies so that the material will flow smoothly into the die cavity. After the billet is heated, it is placed between the upper and lower dies and subjected to extreme pressure, allowing the material to flow into the die cavity and form the required shape. After the part has been forged, there will be some excess material around the die called flash that can be removed by trimming presses. After flash is removed, forged parts will undergo a heat treatment process that may involve solution treatment, quenching and/or aging to achieve the required mechanical properties. After the first round of manufacturing processes, forged parts undergo further machining such as CNC machining or shot blasting following heat treatment until they are considered usable. These secondary processes must produce forged parts that are within the specified dimensional tolerances and/or surface finish standards or requirements. Final inspections and/or tests will include: a dimensional accuracy check; hardness test; tensile strength test; and/or some type of non-destructive testing (NDT) of the forged component to confirm that the forged component is manufactured to specification and is therefore reliable.
Machines Used in Aluminum Forging
In aluminum forging operations, a wide variety of specialized machines are used to increase precision and/or production efficiency: The most common forging presses are hydraulic or mechanical types. Hydraulic presses give a controlled and consistent amount of force, which works well for larger parts, while mechanical presses produce faster cycles making them ideal for mass production quantities. In impact forging operations, forging hammers provide multiple impact blows to the heated metal and shape it effectively. Induction or gas furnaces are used to heat aluminum billets uniformly to a temperature prior to deforming them. After the forging process is complete, trimming presses remove excess flash material to produce the near-net shape of the part. Computer Numerically Controlled (CNC) machining centers are then used for additional precision, tight tolerances, and complex shapes on the parts. Finally, heat treatment furnaces perform solution treatment and aging operations to improve the mechanical strength and performance characteristics of the forged parts.
Tools Used in Aluminum Forging
A whole range of precise tooling is needed to manufacture aluminium efficiently and accurately as well as consistently throughout the whole manufacturing process. Closed die sets are used for producing larger amounts of more complicated parts with strict tolerances, while open tooling is used when producing larger or less complicated pieces and require gradual shaping of the metal. In terms of lubrication, lubrication systems are critical to decreasing the friction between the die and the piece as well as assisting with the flow of the metal, therefore they also help lengthen the life of the die. Trimming dies are used to remove excess flash from the forged part, aiding with the specification of the forged part's final profile. Use of measuring instruments such as vernier calipers and coordinate measuring machines (CMM) will guarantee that all dimensions of the forged parts are accurate and in accordance with the specification. The use of tongs or automated manipulators can help improve safety and efficiency of moving hot billets and forged parts. Of all of the tools used in the forging process the design of the dies will have the most direct effect on the way the metal flows, the orientation of the metal grain, the overall strength and structural integrity of the forged part.
Technologies Used in Aluminum Forging
Advanced technologies have been implemented by modern aluminum forgings manufacturers to improve development, consistency/accuracy, and control throughout the entire operation. Manufacturers utilize CAD/CAM software to produce accurate die designs and detailed component models with optimal geometry and the best possible ability to manufacture. Engineers access simulation software to analyze how metal flows through a die, identify the potential for defects, and evaluate how stress is distributed throughout the entire piece before any actual production occurs (thus, reducing the cost associated with trial-and-error). CNC-controlled presses offer a consistent force during the forging process; accurate stroke lengths throughout the entire process; and repeatable results throughout each manufacturing cycle (producing consistent quality). By utilizing robotic automation to move and handle hot billets, and move new parts from one processing operation to another, companies are able to improve both the level of safety employees have while on the job as well as improving company-wide operational efficiencies. With the use of non-destructive testing techniques such as ultrasonic testing or dye penetrant testing, engineers are able to identify defects on both the inside and outside of a part prior to that part being used in manufacturing. In addition, ERP solutions provide real-time visibility to all parties involved across the supply chain such as planned production, inventory levels, traceability and quality documents, which help facilitate a complete end-to-end view of the entire manufacturing process.
Best Ways to Find Reliable Aluminum Forging Manufacturers
When selecting an aluminum forging manufacturers you should look for one with a successful record of producing high quality products and who can commit to providing a long term supply of those products. Review the manufacturer's experience in relevant industries (i.e., automotive, aerospace, heavy equipment) and evaluate the type of certification (i.e., ISO 9001, IATF 16949, AS9100) showing that they comply with internationally accepted quality standards; also check out their actual capacity (what size/weight presses do they run). What is their maximum tonnage capability? Is there a heat treatment facility located on-site? Is there a machine shop to fabricate tooling? After assessing these items to determine if the potential supplier will meet your requirements, you should then examine the technical capabilities of each supplier. Do they use simulation software to simulate construct?
Do they have CNC controlled equipment and sophisticated inspection systems in place? All of these can provide insight into how well the manufacturer controls its processes and how precisely it produces parts. Also, it's very important to maintain full traceability of materials used in the production process and to issue proper test certificates, so there is no question of a manufacturer being held accountable for their actions. Lastly, reviewing their customer list and looking for established relationships with OEMs will give you additional credibility. This means establishing a facility visit to learn more about the couple of different production systems being used, evaluating the skill set of the workforce, and observing how the different quality processes are executed in the shop. Finally, consider the overall value of the manufacturer in conjunction with price; while the lowest price may appear most attractive, high-quality parts delivered on time and reliable future technical support will always outweigh the immediate cost savings of the lower priced manufacturer.
Conclusion
Aluminum forging is an engineered manufacturing process that creates lightweight but durable components for a variety of industrial applications. Steps consist of (1) heating the workpieces to be forged; (2) deforming workpieces under control with a hammer or a press; (3) trimming the finished forgings; (4) conditioning those forgings; and (5) performing final finishing operations.
Companies producing aluminum forgings today use advanced technology, such as highly developed manufacturing machines, computer-aided design (CAD) die design, simulation tools, and CNC-controlled presses with extensive quality testing and inspection methods to provide an outstanding level of performance.
When establishing an aluminum forge supply chain, the companies making the purchase must look for specific factors related to the technical knowledge and experience of the supplier, their certifications, as well as the strength of their infrastructure and quality assurance systems, rather than simply the end price. A qualified partner in aluminum forgings will provide a long-term, high-performance product that maintains the same performance characteristics throughout the product's life, as well as ensure that the production line maintains its stability over time.
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