Product Description and Process
6061 aluminum cold forging process manufacturer
Production process: metal die forging process, cold heading process
Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc.
Surface treatment process: anodic oxidation, Dacromet coating, paint coating, powder coating, etc.
Product Material and Uses
Normally produce with aluminum 2014, 2017, 2A11, 2A14, 6061, 6063, 6082, 7075, 7A04, etc.
The aluminum forging products are widely used for auto-car parts, truck parts, train parts, vehicle components, aviation industry components, pump & valve components, ejection gun, other machinery components, etc.
Aluminum Alloys Forging
Of the various groups of alloys, the aluminum alloys are most readily forged into precise, intricate shapes. The five most significant reasons are:
They are very ductile at normal forging temperatures
They can be forged in steel dies that are heated to the same temperature as the workpiece
They do not develop scale during heating
They require low forging pressures
They may be forged at high or low strain rates
Aluminum alloys are designated by the four-digit numerical system that is an industry standard for wrought alloys. The numbers are systematically assigned, but do not have any quantitative significance. The first digit indicates the major alloying element, and the last three distinguish the various alloys in the group. For example, the major alloying element in the 2xxx series is copper, in the 6xxx series magnesium and in the 7xxx series zinc.
The major factors influencing the forgeability of aluminum alloys are the solidus temperature and deformation rate. Most of the alloys are forged at approximately 55°C (100°F) below the corresponding solidus temperature.
Most aluminum alloys can be forged in any type of equipment that is used for other metals. However, some grades, such as the 7xxx series, are more deformation rate sensitive and tend to have reduced forgeability when deformation rates are high. Therefore these grades require special care when forged on hammers and high speed presses. Good, continuous lubrication is required because the alloys do not form scale and will seize, gall or cause pressure welding to the die steel if they come in direct contact with it.
Some grades of the 5xxx series may be used in the as-forged condition. All other alloys are generally strengthened slightly in the hot-working range, then subjected to solution heat treating, quenching (usually in water or water-based synthetic quenchants) and subsequently aging at temperatures between 120 and 175°C (250 and 350°F). The aging processes vary from the as-quenched condition to normal aging (T6), or to overaging (T7x), which is done to enhance the stress-corrosion and impact toughness properties with some loss of strength.
Another series of supplemental temper designations denotes when small compressive or tensile deformations are imparted to the forgings after solution treatment. In this case, the supplemental designations are often of a three digit variety (e.g. T-652, T-651). This practice, while adding operations, and hence cost, improves resistance to stress corrosion cracking while not reducing the strength of the forgings.
The strength properties of aluminum alloys are affected by alloy composition, forging process variables and the final heat treatment. Corrosion resistance is affected primarily by alloy composition and the final aging cycle. For example, the 2xxx series, with significant amounts of copper, are generally more prone to atmospheric corrosion, pitting, stress corrosion and galvanic reactions than are zinc-magnesium 7xxx alloys with very low levels of copper.
Aluminum forging alloys 2xxx and 7xxx are used extensively in aerospace applications and airframe structures, due to their favorable high fatigue strength and low density. The 2xxx and 6xxx grades are selected for automotive applications, with the 6xxx grades specified where superior resistance to corrosion is required.
Some of the most commonly forged aluminum alloys are:
Mostly commercial, some aerospace
Mostly commercial, some aerospace
Ideal for processing large pieces of aluminum, open die presses do not constrain the aluminum billet during the forging process and utilize flat dies free of precut profiles and designs. Aluminum blocks weighing up to 200,000 pounds and 80 feet in length can be open-die forged to create large aluminum components with optimal structural integrity. While welding and joining techniques are useful in creating large components, they cannot match the strength or durability of a forged part. Open-die forgings are limited only by the size of the starting stock.
Closed-die forging, also known as impression-die forging, can produce an almost limitless variety of shapes that range in weight from mere ounces to more than 25 tons. As the name implies, two or more dies containing impressions are brought together as forging stock undergoes plastic deformation. Because the dies restrict metal flow, this process can yield more complex shapes and closer tolerances than open-die forging. Impression-die forging accounts for the majority of aluminum forging production.
When industrial applications call for a high strength, circular cross section component, there is no match for rolled-ring forging. The process typically begins with an open-die forging to create a ring preform, shaped like a doughnut. Next, several rollers apply pressure on the preform until the desired wall thickness and height are achieved. Configurations can be flat, like a washer or feature heights of more than 80 inches. Rings can be rolled into numerous sizes, ranging from roller-bearing sleeves to large pressure vessels.
Wheels Built for Speed, Performance and Safety
Professional racecar drivers know that forged aluminum wheels are a great choice for the punishing conditions of competitive racing. Built for speed and performance, forged wheels are extremely lightweight, very strong and exceptionally stiff. Forged aluminum wheels are found off the racetrack too. High performance sports models from Porsche, Lamborghini and Audi can all be outfitted with these sleek and high performance wheels.