The Analysis of Deformability, Structure and Properties of AZ61 Cast Magnesium Alloy in a New Hammer Forging Process for Aircraft Mounts.

Anna Dziubińska,Piotr Surdacki,Krzysztof Majerski

doi:10.3390/ma14102593

Anna Dziubińska, Piotr Surdacki + Show 1 more

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https://doi.org/10.3390/ma14102593

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Abstract

This article presents the analysis of the deformability, structure and properties of the AZ61 cast magnesium alloy on the example of a new forging process of aircraft mount forgings. It was assumed that their production process would be based on drop forging on a die hammer. Two geometries of preforms, differing in forging degree, were used as the billet for the forging process. It was assumed that using a cast, unformed preform positively affects the deformability of hard-deformable magnesium alloys and flow kinematics during their forging and reduces the number of operations necessary to obtain the correct product. Numerical analysis of the proposed new technology was carried out using DEFORM 3D v.11, a commercial program dedicated to analyzing metal forming processes. The simulations were performed in the conditions of spatial strain, considering the full thermomechanical analysis. The obtained results of numerical tests confirmed the possibility of forming the forgings of aviation mounts from the AZ61 cast magnesium alloy with the proposed technology. They also allowed us to obtain information about the kinematics of the material flow during forming and process parameters, such as strain intensity distribution, temperatures, Cockcroft–Latham criterion and forming energy. The proposed forging process on a die hammer was verified in industrial conditions. The manufactured forgings of aircraft mounts made of AZ61 magnesium alloy were subjected to qualitative tests in terms of their structure, conductivity and mechanical properties.

Highlights

An increased interest in magnesium alloys has been noticeable [1,2,3,4,5,6], especially in aviation and the automotive industry [7,8,9]
Forging of the the aircraft mount from AZ61 magnesium alloy from cast preforms of an assumed geomaircraft mount from magnesium alloy from castmaterial preforms of an assumed geometry
The objective of this study was to investigate the formability of AZ61 cast magnesium alloy using the example of an innovative technique for producing forging of aircraft mounts by hammer forging from cast preforms

Summary

Introduction

An increased interest in magnesium alloys has been noticeable [1,2,3,4,5,6], especially in aviation and the automotive industry [7,8,9]. Decreasing the structure mass has become a major priority in many branches of the industry This is why magnesium-based elements made of light metal alloys are increasingly explored in machine construction [10]. Magnesium is a reactive metal and very susceptible to corrosion, especially in environments containing chloride ions, limiting the application area of magnesium alloys. For this reason, it is necessary to protect the surface of magnesium components by applying additional paint coatings, conversion coatings or electrochemical coatings, or by using anodizing processes and vapor deposition of coatings [11,12,13,14].

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