Topic: - Aluminium Forging

 Introduction of Process
 Material Grades Uses in Al forging
 Unique Characteristics of Al Forging
 Application of Forging components
 Aluminium Components details
 Existing Manufacturers and their customer base
 Advantage and disadvantage of Aluminium Forging

The Aluminium Forging Process:

Step 1: Billet Preparation

The first step in the aluminium forging process is billet preparation. A billet is a cylindrical
piece of aluminium that will be forged into the desired shape. The billet is usually pre-
heated to a temperature between 700°F and 800°F to make it more malleable. Pre-heating
the billet also reduces the amount of force required to shape it during the forging process.

Step 2: Lubrication
After the billet has been pre-heated, it is lubricated with a special lubricant. Lubrication is
important because it helps reduce friction between the billet and the forging die. The
lubricant also helps prevent the billet from sticking to the forging die, which can cause
defects in the final product.

Step 3: Forging
The next step in the aluminium forging process is forging. The billet is placed between two
dies that are shaped to the desired form. The dies are then pressed together with a
hydraulic press, which applies compressive force to the billet. The compressive force
causes the billet to flow and fill the shape of the dies.

Step 4: Cooling and Trimming

After the billet has been forged into the desired shape, it is cooled to room temperature. The
cooling process helps to harden the aluminium and increase its strength. After the part has
cooled, it is trimmed to remove any excess material and to ensure that it meets the required
dimensions.

Step 5: Heat Treatment

Heat treatment is a process that involves heating the part to a specific temperature and
then cooling it at a controlled rate. Heat treatment helps to improve the strength, durability,
and other mechanical properties of the aluminium part.

Step 6: Machining
The final step in the aluminium forging process is machining. This involves cutting, drilling,
and otherwise shaping the product to the exact specifications required by the customer.
This step is crucial because it ensures that the final product meets the customer's
requirements and can be used in their specific application.

 Material Grades Used in Aluminium Forging

There are lots of aluminium alloys can be used for drop forging. Main grades in aluminium
forgings include: AL2024, AL5083, AL 6061, AL 6063, AL6082, AL 7075, DTD 5024
 Unique Characteristics of Al Forging

 HIGH STRENGTH
 COST EFFECTIVE
 DESIGN FLEXIBILITY
 LEAD TIME
 EXCELLENT SURFACE FINISH
 FATIGUE RESISTANCE

 Industries Served

Two and Four Wheeler Industry

Two and Four Wheeler Aluminium Alloy forgings such as Under Brackets, Kick Starters,
Crown Forks, bulkheads, wing roots and spars, hinges, engine mounts, beams, shafts,
bell cranks, etc. are manufactured for the Automobile Industry.

Switchgear Industry
Switch gear manufacturers in low, medium and high voltage range covering products like
High Conductivity and Electrolytic Copper Forgings, Medium and High Strength Aluminium
Alloy Forgings. In this field, apart from others. ABB is the consumer of switch gears.

Air Conditioning & Refrigeration Industry

Reciprocating type Gas Compressors for air conditioning and the Refrigeration Industry.

Construction and Mining Tool Industry

We supply in both Alloy Steel as well as forged Aluminium Alloy to various companies such as
Chicago Pneumatic India.

Engine Industry
Forgings in Aluminium Alloys like 7075 & DTD 5024 for Defence Equipment’s, Diesel
Engines and other applications.

Aerospace Industry
The Aerospace Industry, as it stands today, supplies five basic markets: military aircraft,
missiles, space, commercial airliners, and general aviation. Forged Aluminium Alloy is key
to this industry due to its strength, versatility and affordability.
 Forged Aluminium Spray Gun Body

 Forged Aluminium Automotive Suspension Parts

 Forged Aluminium Control Arms

 Forged Aluminium ATV Wheel Spacers

 Forged Aluminium Motorcycle Handlebar Riser

 Forged Aluminium Motorcycle Foot pegs

 Aluminium Forging for Motorcycle Brake Calliper

 Aluminium Forging of Wheel Lug Nuts for Car

 Aluminium Forging of Ring Rolling Aero space

Seamless Rolled Rings, Rings for Slew Bearings, Gear Rings and Y Rings

 Existing Manufacturers and their customer base

1. Sansera Engineering Limited

(CIN:L34103KA1981PLC004542)
Registered Office: Plant 7, No. 143/A, Jigani Link Road, Bommasandra Industrial Area,
Bangalore-560 105, Karnataka, India,
2. CHW Forge Pvt Ltd.

Unit 1, Near Hapur Road Flyover, Maliwara, Ghaziabad –201 001, Uttar Pradesh, India

Customers
 BEML Ltd.
 Komatsu India Pvt. Ltd.
 KYB Conmat India Pvt. Ltd.
 Liebherr India Private Limited
 L & T construction Equipment Ltd.
 Schwing Stetter India Pvt. Ltd.
 TATA Hitachi Construction Machinery Co. Limited

3. Aress High Duty Forgings Pvt. Ltd.

E-27, MIDC, Malegaon, Sinnar, Nashik - 422103

B-101 & 110, Sinnar Industrial Area, Musalgaon, Sinnar, Maharashtra 422113, India

4. Super Auto Forge Private Limited

3/1A, Nedunkundram Village,
Vandalur – Kelambakkam Road,
Kolapakkam,
Chennai - 600127

5. KEMS FORGINGS LTD.

No.96, 2nd Floor, Gandhi Tower, Railway Parallel Road, Kumarapark West, Seshadripuram, Bangalore - 560
020
6. IQS Engineering Solutions Pvt. Ltd.

S. No. 529/1, Shelkewadi, Ghotawade, Tal. Mulshi, Pune – 411042, India

7. Wheels India Limited

 Advantage and disadvantage of Aluminium Forging

Advantage: -
 Light Weight - it has a specific weight of approximately 2.71 g/cm3
 Corrosion Resistance
 Electrical and Thermal Conductivity
 Reflectivity and Ductility
 Odourless and Impermeable
 Recyclability

Disadvantage: -
 Costly
 Strength - unsuitable for certain projects where higher load capacity is needed.
 Welding difficulty - a lower melting point than other metals, Second aluminium has a high thermal
expansion coefficient, which causes serious problems during the welding process
 Fastener Joints - aluminium involves fastener joints that are prone to galvanic corrosion when
coupled with dissimilar metals (such as steel).

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