Forging Condition for Removing Porosities in the Hybrid Casting and Forging Process of 7075 Aluminum Alloy Casting

Chang, Fung-Chi; Hwang, Weng-Sing; Lee, Chung-Ham; Wu, C. S.; Yang, Jin-Bin

doi:10.2320/matertrans.45.1886

Cited by 5 publications

(4 citation statements)

References 2 publications

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“…The alloy used is the A356 modified with strontium which combines good mechanical properties and castability. The forging step enables to close and weld cast shrinkage porosities with good mechanical properties [1,2]. This also allowed a drastic reduction of the wall thickness in the arm.…”

Section: Process Flow Chartmentioning

confidence: 99%

A New Wheel Design for Reducing Weight

Perrier¹,

Bouvier²,

Duperray³

2014

MSF

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Reducing weight is one of the most important challenges in the automotive industry. A wheel design which enables to reduce weight from 13.5 kg to 10 kg is presented. This achievement is possible thanks to the use of a wide variety of technical processes. The disc is manufactured by CobapressTM, a casting/forging process which combines the advantages of a high design freedom, good mechanical properties and the absence of porosities. The alloy used is an A356 aluminum alloy modified with strontium. The rim is made of an AA6082 aluminum alloy which is extruded and flow-formed with a thickness from 3.3 down to 2.2 mm. Finally, the FSW (Friction Stir Welding) allows us to weld the two parts with a cavity to minimize the weight. With this technique the welding of the two different alloys is possible with good mechanical properties, the fracture happens outside of the weld during tensile tests. The final wheels passed bending and radial fatigue tests as well as radial impact tests with success.

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Section: Process Flow Chartmentioning

confidence: 99%

A New Wheel Design for Reducing Weight

Perrier¹,

Bouvier²,

Duperray³

2014

MSF

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“…For this reason, some researchers prefer to process the cast slab directly and have developed a series of processing techniques to do this, such as continuous casting and rolling, casting-forging hybrid forming, and casting/spinning forming, etc. [1,5,34]. Although these techniques pose more severe challenges to the formability of as-cast alloys, several studies have emphasized the feasibility and superiority of the direct hot working of as-cast Al-Mg-Zn-Cu alloys [33,[35][36][37].…”

Section: Introductionmentioning

confidence: 99%

Hot Deformation Behavior and Processing Maps of an As-Cast Al-5Mg-3Zn-1Cu (wt%) Alloy

et al. 2023

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One of the key issues limiting the application of Al-Mg-Zn-Cu alloys in the automotive industry is forming at a low cost. Isothermal uniaxial compression was accomplished in the range of 300–450 °C, 0.001–10 s−1 to study the hot deformation behavior of an as-cast Al-5.07Mg-3.01Zn-1.11Cu-0.01Ti alloy. Its rheological behavior presented characteristics of work-hardening followed by dynamic softening and its flow stress was accurately described by the proposed strain-compensated Arrhenius-type constitutive model. Three-dimensional processing maps were established. The instability was mainly concentrated in regions with high strain rates or low temperatures, with cracking being the main instability. A workable domain was determined as 385–450 °C, 0.001–0.26 s−1, in which dynamic recovery (DRV) and dynamic recrystallization (DRX) occurred. As the temperature rose, the dominant dynamic softening mechanism shifted from DRV to DRX. The DRX mechanisms transformed from continuous dynamic recrystallization (CDRX), discontinuous dynamic recrystallization (DDRX), and particle-stimulated nucleation (PSN) at 350 °C, 0.1 s−1 to CDRX and DDRX at 450 °C, 0.01 s−1, and eventually to DDRX at 450 °C, 0.001 s−1. The eutectic T-Mg32(AlZnCu)49 phase facilitated DRX nucleation and did not trigger instability in the workable domain. This work demonstrates that the workability of as-cast Al-Mg-Zn-Cu alloys with low Zn/Mg ratios is sufficient for hot forming.

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“…The concept of the cast/forge process was proposed by Fujikawa et al [14] Chang et al introduced the cast/forge hybrid process to reduce the porosity of 7075 aluminum alloy castings [15]. The tripods produced with this process were shown at ALUMINUM CHINA 2018, Shanghai, New International Expo Centre (2018/07/ [11][12][13].…”

Section: Introductionmentioning

confidence: 99%

The Optimum Process to Produce High-Strength Cast/Forged Al–8%Zn–2.5%Mg–1%Cu Alloy

Shih

Kwang

Huang

2019

Metals

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Al–8Zn–2.5Mg–1Cu alloy casting blocks were subjected to homogenization and annealing. The treated blocks were then held at different temperatures and forged in different dies to obtain 20 mm-thick plates. After T73 heat treatment, the plates were cut and machined to obtain tensile bar samples that were further subjected to tensile and potentiodynamic polarization tests. Upon analyzing the experimental results, the subzero-treated and forged samples (SO) developed fine grains in their matrix and displayed yield stress (YS) about 400 MPa and an elongation of 11%. The hot-forged samples (HC) displayed a relatively higher YS slightly >440 MPa and a lower elongation of 4%. The intermetallic compound particles confined to the HC decreased its corrosion resistance to be worse than that of the SO. All anodized and sealed samples effectively improved their corrosion resistance. Due to its fine grains, the anodized SO sample produced a higher Icorr than the anodized HC sample.

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Forging Condition for Removing Porosities in the Hybrid Casting and Forging Process of 7075 Aluminum Alloy Casting

Cited by 5 publications

References 2 publications

A New Wheel Design for Reducing Weight

A New Wheel Design for Reducing Weight

Hot Deformation Behavior and Processing Maps of an As-Cast Al-5Mg-3Zn-1Cu (wt%) Alloy

The Optimum Process to Produce High-Strength Cast/Forged Al–8%Zn–2.5%Mg–1%Cu Alloy

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