Aluminium Forging

By Davlen Tandersen
June 2023
What is Forging?
• Forging is a metalworking process that uses compressive force to shape metal
into a desired object. Delivered with a hammer or a die.
• Pressing or rolling metal into shape.
• Forging is often classified according to the temperature at which it is performed;
hot forging, warm forging, and cold forging.
Types of Forging

• Hot Forging
• Warm Forging
• Cold Forging
Hot Forging
• The metal is usually heated (above its recrystallization point), after which it is
struck into a die
• Depending on requirements (specific result, complex shapes, etc.), the die may
also be heated (isothermal forging/hot die forging).
• Average temperatures for hot forging includes;
• Aluminum (Al) Alloys - 360°C (680°F) to 520°C (968°F)
• Copper (Cu) Alloys - 700°C (1 292°F) - 800°C (1 472°F)
• Steel – up to 1 150°C (2 102°F)

Illustration: https://youtu.be/jF7G0feKMSA
Hot Forging
PRO
• It takes less energy (or force) to work
with the material.
• Manufacturers can make more
elaborate shapes than in cold forging.
• An increased ductility.
• During hot forging and subsequent
deformation, pores can reduce (in size)
or close completely.
CONS
• The result of a less precise tolerance
caused by warping and thermal
contraction. This is caused in instances
where uneven cooling is present.
• Possible for the undesirable reaction
between the forged metal and the
surrounding atmosphere.
Warm Forging
• Intermediate forging temperature between cold and hot, semi-hot forging
• Warm forging is used as an alternative to cold forging or combined with cold
forging.
• It lies between the cold forging process (performed at or near room
temperature) and the hot forging process (performed at temperatures above
the material’s melting temperature).

Warm Forging for Common Rail (fuel injection system)

Warm Forging

PRO
• Lower forming forces, not as soft or
malleable as they would at higher
temperatures.
• Improves the material's plasticity and
ductility compared to cold forging.
• Increase dies lifespan, less thermal
stress on the dies.
• Less energy compared to hot forging,
more energy efficiency.
CONS
• High tooling cost
• Difficult to maintain precise and
consistent temperatures. Need to avoid
overheating or cooling, since it could
affect the quality of the part.
Cold Forging
• More Specialized types of forging
• Bar stock is inserted into a die and squeezed into a second closed die at room
temperature.
• Typically used for smaller parts that do not require high temperatures.
• Cold forging involves placing bar material in a die and pressing it vertically with
a second closed die.
• Preferred for Aluminium (softer metal)

Illustration: https://youtu.be/EKsiT_-swBM
Cold Forging

PRO CONS
• No heating; saves energy. • May require heat treatment
• Efficient for high-volume manufacturing. • Because of the higher forces required in
• No shrinking from thermal processes. this process, heavier/more powerful
• Superior dimensional accuracy and equipment and stronger tools are
better surface finish. needed.
• Ensures that no air bubbles, porosity, or
other impurities are trapped within the
material
• Cost-effective and eco-friendly.
 Types of Process

• Press Forging (Open-die & Closed-die Forging)

• Drop Forging
Press Forging vs Drop Forging
Press Forging Drop Forging

Drop Forging: https://www.youtube.com/shorts/eflDXWt9Xd0

Press Forging vs Drop Forging
Press Forging
1. In press forging, metal is shaped by means
of a single and continuous stroke. Pressure
applied is slow, steady, and continuous in a
single squeezing action
2. This process is faster and has higher
production rates.
3. Initial cost is higher
4. Deformation obtained is uniform,
simultaneous & deep penetrating at the
center of the metal part.
Drop Forging
1. In drop forging, the metal is shaped by
means of a series of blows. Pressure
applied is impact and in multi-stroke in
drop forging.
2. This process is a slow process & has
moderate production rates.
3. Initial cost is less.
4. Deformation of metal is more at surface
layers than that of center of the metal part.
Press Forging: Open-die Forging vs Closed-die Forging
Open-die Forging Closed-die Forging

Open-die Forging vs Closed-die Forging: https://www.youtube.com/watch?v=YobXFODkp50&ab_channel=MechanicsMix

Press Forging: Open-die Forging vs Closed-die Forging
Open-die Forging Closed-die Forging

1. Workpiece is compressed between 2 flat 1. Workpiece is compressed between 2

dies. impressed dies.
2. After the process, the machining of 2. After the process, the machining of
components is required. components is not required.
3. Suitable for simple components. 3. Suitable for more complex components.
4. Process used for low quantity production. 4. Process used for high quantity production.
5. Cost of dies is low. 5. Cost of dies is high.
6. Process is simple. 6. Process is complex.
Aluminium Forging Defects

• Cold shut
• Die shift
• Cracks
• Unfilled section
• Scale pits
• Flakes
Aluminium Forging Defects
Cold Shut
Causes:
• Excessive chilling of the forge products.
• Improper die design.
• Sharp corners.
Effects: Reduce strength and stability of the part. Also, degrade the visual appearance.

Die Shift
Causes: The dies used for the process are misaligned
or move during the process.
Effects: Improper shape and size of the forged metal,
and lead to surface defects.
Aluminium Forging Defects
Cracks
Causes:
• Too much tensile stress in the material.
• Forging part is not properly designed, or the material
is not properly processed.
Effects: Reduce strength, ductility, and corrosion resistance of the results.

Unfilled Section
Causes:
• Poor die design and improper heating.
• Insufficient raw material.
• Inadequate forging pressure
Effects: Product with weak structures and reduced durability
Aluminium Forging Defects
Scale Pits
Causes:
• Forging is carried out in an open environment
(outdoor, humid and high temperature environment).
• Improper cleaning of forged surface.
• Oxidation occurs
Effects: Appearance and performance can be affected, more likely to break and crack.

Flakes
Causes: Improper cooling of the workpiece.
Effects: Reduction of the strength of the material and
it more prone to failure
Raw Material Storage Issues
Few factors of raw material storage that could affect the Forging part result:
• Temperature
If the raw materials are stored at storage with too high or too low of
temperature, it can affect their properties and make them more difficult to forge.

• Humidity
A humid environment can corrode or rust the material which can weaken them
and more likely to crack during forging.

• Presence of contaminants
If the materials are stored in storage with contaminants such as dust or dirt, they
could get into the material and weaken them.
Forging vs Casting
Forging vs Casting
Forging
• Toughness: The material is more resistant to
physical damage, including impact damage,
and deformation.
• Resistance to Wear: The grain structure
aligns with the form of the piece, reducing
the risk of wear.
• Strength: Forged metals have more relative
strength than cast and plate metals, even
when the parts are formed using the same
alloy.
• Reduced Likelihood of Defects: Other
processes may result in metal pieces with
shrinkage and cold pour issues, cavities
within the cast, or porosity.
Casting
• Fewer Size and Complexity
Restrictions: Castings can be done for parts
of virtually any size or complexity level.
• Metal Options: Castings can be made with
a wider range of specialty alloys because
chrome, nickel, and molybdenum can be
more easily incorporated into the molten
metals during the casting process.
• Low-Volume Production
Capabilities: Castings can cost-effectively
produce small production runs, especially
because the tooling is cheaper than that
for equivalent forging dies.
Forging Application
Some common examples include:

Gears Crankshafts Piston

Aircraft Automobile Sporting

Components Components Goods
Aluminium Forging Sample Photo

Sanwei’s sample (P/N: 01575179)

Supplier: JYFA
Customer: Ricardo
Sanwei Forging Supplier List
• JYFA 晉燁
http://www.jyeh.com.tw/

• KZI 慶榮發
https://www.kzi-forge.com/

• Liow Ko 六哥
https://www.liowko.com.tw/
Discussion