Liquid Forging Research Articles

Study on the Effects of the Indirect Liquid Forging Die Life

In this paper, the influence factors of liquid die forging die life are talked about, mainly for example with the key universal parts Squeeze chamber of indirect liquid die forging. In the Premise to guarantee product quality, the mould preheating temperature, pouring temperature, casting alloy type, suitable and reliable cooling methods and effective paint could influence bigger on the peak and variation range of the mold temperature. These factors should be taken into consideration and remembered its effects for mould design in order to improve die life, further a new direction and thinking of liquid forging die life design criterion will be given.

A Review of Liquid Forging Process

Liquid forging is a new technology of plastic forming. It is a kind of bulk forming process with liquid metal with high-quality and efficiency and it has the characteristics of both die casting and forging. This paper will discuss the liquid forging process, die design, simulation and optimization of liquid forging [1].

Influence of Different Modificatior on Structure and Mechanical Properties of Liquid Forging Aluminum Alloy

Based on the experiment,the forming properties of Aluminum alloy in liquid forging was studied by adding rare-earth metal Y (Yttrium) modificatior and ternary modificatior(25% NaF +62% NaCl +13% KCl).The structure and mechanical properties of the prepared samples under two modifications were compared.The results showed that the rare-earth metal Y can modificatior liquid aluminum alloy forging a comprehensive mechanical properties of a substantial increase, the use of rare-earth metal Y (Yttrium)modificatior was better than ternary modificatior.

Development Status and Applications Prospect of Squeeze Casting Technology

Squeeze casting(liquid forging), a process technology that combines casting- forging and near net-shape high-quality engineering components，is always subjected high attention of the industrial circle. The squeeze casting technology which refers to improve the products properties and expand the applicable range of the squeeze casting is developing fast. With the Flourishing development of car industry and the constant renewal of National Defense Equipment, it raises a new requirement for squeeze casting industry. This paper discusses the process technology and casting machine of domestic and overseas.

Effect of Heat Treatment on the Organization and Properties in Liquid Forging

In this paper, based on the liquid forging part flange LY12, the influence of heat treatment on the organization and performance of the liquid forging part was studied through microstructure, mechanical properties and tensile fracture surface analysis methods, this article also has some guiding significance to the formulation of the best liquid forging process parameters. The results show that the sample after natural aging which mechanics performance is best, and grain is relatively small; the latter two that after artificial aging are relatively poor. With the extension of artificial aging time, the mechanical properties and the organization has a descending trend.

The Influence of Specific Pressure on the Organization and Properties in Liquid Forging

In this paper, based on the liquid forging part flange LY12, the influence of specific pressure on the organization and performance of the liquid forging part was studied through microstructure, mechanical properties and tensile fracture surface analysis methods, this article also has some guiding significance to the formulation of the best liquid forging process parameters. The results show that the tensile strength, hardness and elongation of the parts raise with the specific pressure increasing, the organization has also been significant refinement and improvement.

Study on Microstructures and Mechanical Properties of AlSi9Cu3 Aluminum Alloy Fabricated by Liquid Forging

Study the properties of AlSi9Cu3 aluminum alloy test bars fabricated by liquid forging with instruments such as optical microscope, direct reading spectrometer and micro-controlled electronic universal testing machine. Further more，analyze the microstructure and forming mechanism of AlSi9Cu3 aluminum alloy fabricated by liquid forging, the study shows : AlSi9Cu3 aluminum alloy fabricated by liquid forging has excellent performance and good prospects in production.

Homogenization on microstructure and mechanical properties of 2A50 aluminum alloy prepared by liquid forging

The homogenization on microstructure and mechanical properties of 2A50 aluminum alloy prepared by liquid forging was investigated. Wheel hubs were produced using direct and compound loading. The results show that the microstructure and mechanical properties are inhomogeneous in direct forged samples. The microstructure of the wall is coarser than that of the base, and the mechanical properties are lower and some defects are detected at the wheel corner. Using compound loading, the microstructure and mechanical properties of the wall are improved evidently. With increasing feeding amount, the microstructure and mechanical properties become more homogeneous. The defects disappear when the feeding amount is 4 mm. The forged wheel hubs could obtain fine and homogeneous microstructure with grain size of 20-30 μm, tensile strength of 355 MPa and elongation of 10% when the feeding amount is 10 mm. The microstructure and mechanical properties of liquid forged workpieces could be controlled and homogenized using compound loading.

Research of SiC<sub>P</sub>/2A50 Composite Materials Creeper Treads Prepared by Liquid Forging

Microstructure of creeper treads is inhomogeneous when they are produced by way of common casting, which lead to lower mechanical properties. Compound loading and feeding are introduced into the technology of liquid forging. Defects of filling incompletely, shrinkage porosities and cavities are usually appeared in raised part of creeper treads. With feeding amount increased above 5mm, plastic deformation also would be increased, so the microstructure and mechanical properties of raised part were improved and those defects disappeared meanwhile. SiCP/2A50 composite materials were used in order to enhance abrasive resistance and extend their service life. Creeper tread produced by compound loading and feeding could obtain homogeneous and fine microstructure. Average tensile strength and hardness of specimen reached 360MPa and HV115.97 respectively after (500°C×3h) solution treatment, (20min) quenching and (160°C×10h) artificial aging. The results show that inhomogeneous character of microstructure and mechanical properties of creeper treads could be overcome by compound loading and feeding.

Spin Formability of Al-6061 Aluminum Alloy Pre-Forms Obtained via Liquid Forging

There are growing demands from the precision engineering industries for components that are net or near net shape while striving to reduce material wastage during the manufacturing process. This study investigates the spin formability of liquid forged Al-6061 pre-forms into near net shape cylindrical components with high aspect ratios. The liquid forging process offers very significant materials savings by providing pre-forms for the spin forming process. The end products are near net shape components with very good mechanical properties. Results from this study indicate that liquid forging is able to supply Al-6061 pre-forms, otherwise machined from solid bars, which are sufficiently formable for spin forming. The microstructure of a spin formed liquid forged pre-form is also indiscernible from that of a fully machined pre-form from extruded bar stock. As such, spin forming of liquid forged pre-forms has the potential to reduce material wastage and hence production costs.

Mechanical Properties and Microstructure of Aluminum Alloy Al-6061 Obtained by the Liquid Forging Process

The liquid forging process has the flexibilities of casting in forming intricate profiles and features while imparting the liquid forged components with superior mechanical strength compared to similar components obtained via casting. Additionally, liquid forging requires significantly lower machine loads compared to solid forming processes. Currently, components that are formed by liquid forging are usually casting alloys of aluminum. This paper investigates the suitability of liquid forging a wrought aluminum alloy Al-6061 and the mechanical properties after forming. The proper handling of the Al-6061 alloy in its molten state is important in minimizing oxidation of its alloying elements. By maintaining the correct alloying composition of Al-6061 after liquid forging, these Al-6061 samples can subsequently undergo a suitable heat treatment process to significantly improve their yield strengths. Results show that the yield strengths of these liquid forged Al-6061 samples can be increased from about 90MPa, when they are in the as-liquid forged state, to about 275MPa after heat treatment. This improved yield strength is comparable to that of Al-6061 samples obtained by solid forming processes. As such, the liquid forging process here has been shown to be capable of forming wrought aluminum alloy components that has the potential for structural applications.

Liquid forging of thin Al–Si structures

Liquid forging is a pressurized solidification process, wherein finished components can be produced in a single process from molten metal to solid, utilizing re-useable die tools. In conventional die casting (gravity and pressure), components with a minimum wall thickness of about 0.6 mm can be fabricated. However, parts with section thickness as thin as 0.2 mm can be liquid forged using near eutectic Al–Si or Al–Si–Cu alloys. Water based lubricant containing micrographite is effective in releasing the component during ejection. In addition, it aids in shaping the component to required dimensional accuracy. These liquid forged parts are pore free. Thermal analysis of liquid forged 0.8 mm plate revealed rapid freezing at the rate of about 700 °C/s. During the process, die and punch were maintained at 200–250 °C. X-ray residual stress analysis on the surface of the liquid forged plate showed high intensity values for 0.1 mm plate. Distribution of eutectic silicon at inter dendritic region is extremely fine to nanoscale level.

Feasibility study on the Laser Aided Additive Manufacturing of die inserts for liquid forging

This paper reports the Laser Aided Additive Manufacturing of nickel-base alloy Nimonic 80A for the purpose of direct building of die inserts for liquid forging. Low porosity level of 0.01–0.04% with reasonable deposition rate was achieved. The micro-hardness showed very good homogeneity. Directionally solidified cellular micro-structure with an average size of 5 μm was observed. Very fine MC-type carbides were detected at the grain boundaries, which function as the strengthening phase of the alloy.

RECENT DEVELOPMENTS IN THE MANUFACTURING OF COMPONENTS FROM ALUMINIUM-, MAGNESIUM- AND TITANIUM-BASED ALLOYS

Recent developments in the field of manufacturing techniques and alloy development of light materials are reviewed. In the field of manufacturing Aluminium based components, special attention is given to casting, including liquid forging and semi-solid forming technology while for sheet metal forming technology the focus is on material properties and process technology in superplastic forming. For the manufacturing of Magnesium-based components, special attention is given to casting processes and alloy development for casting. For wrought Magnesium, material properties control is covered. For Titanium-based components, an overview of the latest additions to high strength alloys are given, including non-linear elasticity as demonstrated by materials like GUM Metal™. Advanced forming technology such as Levi Casting are also treated.

Forging process of medium-pressure-type rheology materials fabricated with electromagnetic stirrer

This paper describes a rheo-forming process for the development of automobile suspension parts by using rheology material with electromagnetic stirring equipment. Generally, the liquid forging process takes place under high pressure of 1,000 bar. The productivity of the liquid forging is higher than that of the lower pressure die-casting. In order to improve mechanical properties, the rheology forging process by using medium pressure (<500 bar) with electromagnetic stirring equipment has been proposed for fabrication of rheology material with controlled solid fraction. From the analysis of filling and solidification, the die design of medium vertical forging process by electromagnetic stirrer equipment has been proposed for the development of an arm part. The microstructure and mechanical properties of suspension parts were investigated with and without heat treatment. Based on the microstructure, observation revealed the arm part with fine and spherodized α-Al phase particles. As a result, the uniform eutectic structure enhanced the mechanical properties of the suspension part.

TRACTION BREAK SURFACE ANALYSIS OF THE Al-Zn COMPOSITE STRENGTHEN WITH CARBON FIBER

In this article are presented the results of the research about strengthening piece avulsion from the metallic matrix of Al and Al-50%Zn that are obtained after the traction break. The results are legitimated about the aluminum carbide from the matrix- strengthening piece interface. Composites are obtained by liquid forging. And the strengthening piece is unidirectional aligned. The temperatures for the premolding preparation were about 20oC, 600oC and 900oC. During the heating and the manipulations, it worked continually under the neuter argon atmosphere to protect these highly reactivity oxygen fibers. Measurements were made on test-pieces tear to pieces by traction break into longitudinal sense of strengthening piece. After the test, surface was covered with a silver layer, witch was dreg from steam phase. Fibers were included into a transparent resin and after the splitting extraction length measurement was made. In this paper are presented fibers avulsions from aluminum matrix (maximum quantity of aluminum carbide from strengthening piece interface have the result of an strong adhesion and therefore fibers will tear into matrix breaking section plan) respectively 50% Zn alloy aluminum matrix (Aluminum carbide cause an medium adhesion into interface and fibers tears into pieces according with histogram). Also are presented SEM microscopy of the Al matrix samples and 50%Zn alloy aluminum matrix.

Fabrication of fiber reinforced metal matrix composites by squeeze casting technology

Squeeze forming process is a special casting technique that combines the advantages of traditional high pressure die casting, gravity permanent mold die casting and common forging technology. It is a relatively new casting process. It is otherwise called squeeze forming, liquid forging, liquid pressing, extrusion casting, liquid metal stamping, pressure crystallization and corthias casting. The above said process was first discovered by the Russians and later it was developed in countries like USA, Europe and Japan. This advanced casting method is applied for processing of both ferrous and non-ferrous materials besides composites. The major advantages of this technology are elimination of porosity and shrinkage, 100% casting yield, attainment of greater part details, good surface finish, good dimensional accuracy, high strength to weight ratio, improved wear resistance, higher corrosion resistance, higher hardness, resistance to high temperature, improved fatigue and better creep strength. The components manufactured by this casting method requires lesser post machining operation and they have improved mechanical properties like higher strength and ductility. In squeeze casting process the liquid metal is pressurized while they solidify and hence near net shapes can be produced with sound and dense quality. The microstructural refinement of squeeze cast products is desirable for many critical applications. This process is simple, economical and it can be automated easily. The process generates the highest mechanical properties attainable in a cast product. So this process has been adopted to make composite castings at an affordable cost. This paper reviews about the principles of squeeze casting technology, which can be applied to process discontinuous fiber reinforced metal matrix composite castings. Besides this article highlights the type of engineering components produced by this advanced casting method.

Mechanical Characteristic of Flowing Solidification under the Extrusion for the Mixture of the Liquid Aluminum with Sillimanite Particles

: According to the theory of liquid metal forging and liquid metal extrusion, a new kind of fabricating method for particles reinforced metallic matrix composite was put forward by author. In this paper, the extrusion process to semisolid thick liquid after the mixture was studied by means of the theoretical analysis and experimental methods. Mechanical characteristics of solidification during flowing and plastic deformation during solidification of the composite were found. So the base was built up for selecting technology parameters and for building a stabile process

Thermal Analysis of Flow in the Deformation Phase of Liquid Lubricated Plane Strain Forging

The generalized energy equation is reduced into a simple form for conduction and convection modes of heat transfer across a hydrodynamic incompressible fluid film in the deformation phase of plane-strain forging. Expressions for the temperature, velocity, and flow distributions are obtained by solving the energy equation with appropriate boundary conditions. Application of this analysis is illustrated for the film formation process in the deformation phase of liquid lubricated plane strain forging. The analysis indicates that the Peclet number plays an important role in deciding the variation of lubricant film thickness with position and time in the deformation phase. [S0742-4787(00)02504-2]

The Influence of Liquid Extrusion on the Microstructure and Properties of an Al-Si Alloy

Based on the study of the theory and practice of liquid forging and solid extrusion, liquid extrusion technology has been developed by combining the characteristics of both. By this technology, a tube, a bar, or other shapes can be produced in a single process, and the properties of many kinds of experimental materials are significantly improved. An Al-Si alloy has been used as an experimental material for studying the effect of the liquid extrusion process on casting alloys, and the properties and the microstructure of the alloy have been improved. Compared with permanent mold casting, the tensile strength is raised by 60%, the specific elongation is increased 15 times and impact resistance is increased even more. Correspondingly, the grain structure becomes finer and the silicon and AlFeMnSi phases are smaller. The strengthening mechanism of liquid extrusion has been expounded theoretically. A factor of 2 increase of strength by the liquid extrusion process has been described.