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Aluminum Forging

Aluminum forging is a process that involves shaping aluminum using compressive forces applied through dies or molds. The process is used to create a wide range of parts and components used in various industries, including aerospace, automotive, construction, and more. Aluminum forgings are valued for their high strength-to-weight ratio, corrosion resistance, and excellent thermal conductivity, making them ideal for use in many applications.

CFS Forge is a leading provider of aluminum forging services, offering a wide range of capabilities to meet the needs of customers in various industries. With over 20 years of experience in the field, CFS Forge has established a reputation for producing high-quality aluminum forgings that meet or exceed customer expectations.

The Aluminum Forging Process: Step by Step

Aluminum Forging

Step 1: Billet Preparation
The first step in the aluminum forging process is billet preparation. A billet is a cylindrical piece of aluminum that will be forged into the desired shape. The billet is usually pre-heated to a temperature between 700°F and 800°F to make it more malleable. Pre-heating the billet also reduces the amount of force required to shape it during the forging process.

Step 2: Lubrication
After the billet has been pre-heated, it is lubricated with a special lubricant. Lubrication is important because it helps reduce friction between the billet and the forging die. The lubricant also helps prevent the billet from sticking to the forging die, which can cause defects in the final product.

Step 3: Forging
The next step in the aluminum forging process is forging. The billet is placed between two dies that are shaped to the desired form. The dies are then pressed together with a hydraulic press, which applies compressive force to the billet. The compressive force causes the billet to flow and fill the shape of the dies.

Step 4: Cooling and Trimming
After the billet has been forged into the desired shape, it is cooled to room temperature. The cooling process helps to harden the aluminum and increase its strength. After the part has cooled, it is trimmed to remove any excess material and to ensure that it meets the required dimensions.

Step 5: Heat Treatment
Heat treatment is a process that involves heating the part to a specific temperature and then cooling it at a controlled rate. Heat treatment helps to improve the strength, durability, and other mechanical properties of the aluminum part.

Step 6: Machining
The final step in the aluminum forging process is machining. This involves cutting, drilling, and otherwise shaping the product to the exact specifications required by the customer. This step is crucial because it ensures that the final product meets the customer's requirements and can be used in their specific application.

Aluminum Forging Alloys

Aluminum Forging Alloys

 There are lots of aluminum alloys can be used for drop forging. Main grades in aluminum forgings include: AL2024, AL5083, AL 6061, AL 6063, AL6082, AL 7075, etc.

Alloys Chemical Compositions (GBT 3190-2008)
Si Fe Cu Mn Mg Cr Zn Ti Al
2024 0.50  0.50  3.8-4.9 0.30-0.90 1.2-1.8 0.10  0.25  0.15  Balance
5083 0.40  0.40  0.10  0.40-1.0 4.0-4.9 0.05-0.25 0.25  0.15  Balance
6061 0.40-0.8 0.70  0.15-0.40 0.15  0.8-1.2 0.04-0.35 0.25  0.15  Balance
6063 0.20-0.60 0.35  0.10  0.10  0.45-0.9 0.10  0.10  0.10  Balance
6082 0.7-1.3 0.50  0.10  0.40-1.0 0.6-1.2 0.25  0.20  0.10  Balance
7075 0.40  0.50  1.2-2.0 0.30  2.1-2.9 0.18-0.28 5.1-6.1 0.20  Balance

Differences Between Aluminum Forging Alloys and Aluminum Die Casting Alloys

First of all, forging and die casting are two kinds of different forming processes for aluminum alloy components. Based on different manufacturing methods, the aluninum alloys used are also different.

Aluminum forging alloys include A1--Si--Mg--Cu alloy and A1-Cu-Ni-Fe alloy, the commonly used aluminum forging alloys are 6061, 6063, 6082, 7075, etc. Their thermoplasticity is excellent, so the forging performance and mechanical properties are good. This kind of alloy is mainly used for making aluminum forgings that can bear the load and have complex shapes.

Aluminum casting alloys include four major categories: A1-Si alloy、A1-Cu alloy、Al-Mg alloy and Al-Zn alloy. For casting aluminum alloys, in addition to the necessary mechanical properties and corrosion resistance, they should also have good casting performance. In cast aluminum alloys, the best combination of casting properties and mechanical properties is A1-Si alloy.

By comparision, aluminum alloy forging can advoid defects caused by casting. What's more, the mechanical properties of aluminum forging are much better.

Aluminum Forging Benefits

There are lots of advantages in aluminum forging. First of all, as the internal organization of aluminum forging alloys is fine and uniform, they can be forged in various shapes with little to no machining allowance, which can greatly save labor cost and production time. Secondly, the thermal conductivity of aluminum forgings is good. Thirdly, forged aluminum parts have high density, no loose, pinhole, no air hole on the surface, with good surface treatment performance. In short, aluminum forgings has light weight, high strength, high toughness, excellent fatigue resistance and corrosion resistance, good thermal conductivity, easy to machining.
  • As an economic means of designing and making a shape. Machining can be eliminated and a high production rate can be achieved. Designs can be produced that eliminate the need for joints and welds.
  • A high strength to weight ratio can be achieved. The act of forging produces a fully wrought structure improving the shock resistance and fatigue resistance.
  • The surface finish is good and the elimination of porosity ensures pressure tightness. This combination of good mechanical properties, dimensional accuracy and surface finish means that aluminium forgings are used in highly stressed parts where structural integrity is of paramount importance. The alloys commonly used for these highly stressed applications are from the 2000, 6000 and 7000 series. The aerospace industry is a major end user.
  • More advantages of aluminum forging... 

Post Processing of Aluminum Forging

Heat Treatment: T6 Heat Treatment

Heat Treatment for Aluminum Forgings

Like steel forgings, aluminum forgings may also require heat treatment to achieve a certain properties. T6 heat treatment is the typical heat treatment way after aluminum forging.

Heat treating of aluminum forgings depends to a great extent on the type and grade of aluminum forgings.  Main purpose of heat treating stainless steel castings is to relieve stresses, improve mechanical properties or facilitate machining. The processes generally produce nearly uniform properties throughout the forging, and are not used for localized effects such as surface hardening.

Note: Before heat treating operation, surface cleaning is necessary performed on aluminum forging blanks to remove oils, grease, and other types of residue. Left on the aluminum forging surface during heat treating may affect the properties of products.

Post CNC Machining

CNC Machining of Aluminum Forgings

Although aluminum forgings after closed die forging process can achieve a higher size accuracy and surface finish, it does not mean machining can be saved for all the aluminum forged products. Machining will have to be performed when there is a closer tolerance and surface finish requirement that forging can not meet.

Our drop forging factory has built a reputation to do machining after aluminum forging. Our specialized machining services enables us to manufacture aluminum forgings with intricate geometry and detail, while maintaining high precision and accuracy. Our company has equiped with full sets of machining equipmement from manual turning & milling to complex CNC machining services. We offer the capabilities to machine aluminum forgings from several ounces up to 50lbs.

Inspection after machining is also very critical, we utilize manual inspection equipment and gages as well as the latest in coordinate measuring machine (CMM) technology to measure and record all the dimensions. This ensures our customers always get the quality they want.

Surface Finishing

Surface Finishing of Aluminum Forgings

Surface finishing is very popular post treatment method to smooth the surface of aluminum forgings. See the types of surface treatment for aluminum forgings in below:

Shot blasting:
The most widely used surface treatment method used to clean, or polish the surface of stainless steel castings. Low cost.
Sand blasting:
A kind of surface treatment that refines the surface of aluminum forgings. The surface smooth of sand blasting looks better than that of shot blasting, but higher cost.
Anodization treatment: Used to remove surface tiny burrs and improve the brightness of aluminum forgings. The surface looks smooth and a bit shining.
Mechanical Polishing: The most smooth and shiny surface treatment method, but costs high.

Aluminum Forging Company

CFS Drop Forge is one of the largest aluminum forging company in China. We can supply custom forging and machining service ranging from 0.05kg-10kgs that match your exact design specifications with any aluminum grade required.

Why us?
  • Advanced Manufacturing Process & Fast Delivery:  Unlike some small aluminum forging companies in China, all the production equipments used in our aluminum forging process are imported and checked regularly. Besides, we continuously study foreign advanced production experience to improve our strength. This will enable our customers to achieve superior quality, fast delivery, but lower price compared to purchasing aluminum forgings from Eourpean or American Markets.
  • Full Solution: CFS is not only limited to aluminum forging, we also have the capabilities of heat treatment, post machining, surface treatment to supply finished products to our customers. What’s more, we can also supply redesign service for free if the design is not so ideal for aluminum forging production.
  • District Quality Control: Quality control is also critical during the whole manufacturing process. CFS Drop Forge follows three times' inspection before shipment: initial inspection, routing inspection and final inspection. And the related testing reports will be submitted to our customers.
  • Convenient Transportation: Our company is located in the second largest port city of China, so our customers can enjoy convenient waterway transportation if purchasing forgings from us. Especially for large volume, it can help to save a lot of shipping cost and time for our customers.
Our mature forging technique makes us the most reliable one-stop source for our customers. The competitive prices and full services on aluminum forging are the most attractive factor for foreign companies from USA, UK, Canada, Australia, ect to purchase products from our company in China. Need to source aluminum forging service in China? Contact us now!

We mainly produce OEM and Aftermarket aluminium forgings for automotive industry, aerospace industry, pipe fittings and other industries with high quality and very competitive price. Pls contact us if you have such purchasing demands.

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