In elemental form, aluminum is a lightweight and soft metal. It is most commonly alloyed with tin, magnesium, zinc, or copper. This increases the workability, mass, durability, and strength of the original material. The majority of aluminum parts are created through a method known as forging.
Aluminum alloy forgings are among the easiest to accomplish. Products made from cast aluminum generally have a low melting point, making them more cost-effective, but the tensile strength is also low.
Aluminum parts are made using a closed die forging process. Typically, there are two different types of forging methods used, which are cold forging and hot forging.
Hot Forging
The process for hot aluminum alloy forgings involves heating aluminum bars to high temperatures. Once the forging is complete, the aluminum’s grain structure is homogenized and broken down into much finer grains. This enhances the yield strength, toughness, and ductility of the aluminum alloy forgings. Because hot forging produces little to no scrap, it is among the most efficient methods for producing aluminum alloy forgings.
Cold Forging
Another method for creating soft, easy-to-work-with aluminum parts is cold forging. Even less expensive than hot forging, the result of cold forging is a precision product requiring very little finish work. This is the preferred method when the project calls for symmetrical products.
The process starts with aluminum bar stock being bent to shape and smashed in a die. This refines the shape. Heat treatment can then be used to strengthen the aluminum alloy forgings.
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