Aluminum alloy products are generally manufactured by gravity or low pressure casting process. The product size is large, the materials used are relatively loose, and the structure is relatively loose. The pores will be left inside the casting. The existing inspection equipment cannot completely detect defects, and the strength and elongation of the castings There are certain limitations. In order to ensure the quality of the product, the product size is considered too large in the design, the material is too large, and the internal organization of the product is loose, the surface is prone to oxidation and corrosion, and there will be potential safety hazards in long-term operation. Solid-state die forging is a high-efficiency and energy-saving material processing cutting-edge technology, which refers to the use of high-strength dies on special die forging equipment to make metal blanks press in the die cavity to produce plastic deformation to obtain the required shape, size and internal quality of forgings. process method. Aluminum alloys prepared by solid-state die forging have significant advantages such as high strength, smooth surface, small processing volume and less material required.
Since the United States first used solid-state die forging technology to manufacture fighter jets in 1951, aluminum alloy solid-state die forging technology has developed rapidly. The microstructure of solid die forging aluminum alloy is different from that of gravity casting and low pressure casting aluminum alloy. The former is broken grain and forged structure, and the latter is dendritic grain and as-cast structure. In terms of mechanical performance indicators, the strength of solid die forging aluminum alloys is generally increased by 30% to 50% compared with gravity casting and low pressure casting aluminum alloys. At present, developed countries such as North America, Europe and Japan have widely used aluminum alloy forgings, and are widely used in the automobile manufacturing industry. Compared with the casting process, the die forging process reduces the cost of aluminum alloy materials by 25% and the gravity by 43%.
The development of China's aluminum alloy solid-state die forging technology began in the 1970s, and has been gradually applied in the aviation field since the 1990s. In the past decade, China's aluminum alloy solid-state die forging technology has made great progress, and has now begun to be used in the automobile manufacturing industry. Promote the application. At present, the consumption of aluminum alloy forgings per car in China is only 25kg, and it will reach 130kg in the next few years. In terms of mechanical performance indicators, forgings can generally be increased by 30% to 50%, and individual indicators can even be several times higher, such as elongation, which can reach about 4 times, which greatly improves fatigue resistance.
Item | Casting Aluminum alloy（ZL101A） | forging Aluminum alloy（6082） |
heating temperature/℃ | 660 | 480 |
hardness/HB | 75 | 110 |
tensile strength/MPa | 230 | ≥392 |
Yield Strength/MPa | 210 | ≥345 |
Elongation/% | 3 | 15 |
environmental protection | The heating temperature is high, melting is required, and the production process causes great environmental pollution | The heating temperature is low, and no melting is required, and the environmental pollution is minimal |
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