Defects Produced by Improper Forging Process
Forging is a manufacturing process used to shape and form metal into the desired finished product. The process requires high pressure to place the metal into the desired shape and it is highly dependent on proper technique and material properties. It is possible for improper forging to take place which can have a wide range of effects on the integrity of the metal. The following article will discuss some of the most common types of defects that can be caused by improper forging, as well as potential solutions.
Cracks
One of the most common defects that can occur in improperly forged metal is a crack. Cracks are formed in metal due to either stress or fatigue. Stress occurs when the metal is subjected to a great amount of force greater than the metals ultimate tensile strength. Fatigue occurs when the metal is subjected to repeated loading and unloading of the same stress level. Improperly forged metal is more likely to form cracks due to the higher stresses used in the process.
If a crack does form it is essential that it be repaired quickly to prevent any further damage to the metal. Repairs can be made using a variety of methods including welding, rivets, or a specially designed adhesive. The type of repair used will depend on the size and location of the crack, as well as the type of metal.
Surface Defects
Another common type of defect that can occur in improperly forged metal is a surface defect. This can include pitting, grooving, and burning. Pitting occurs when the metals surface is eroded due to the high temperatures and pressures of the forging process. Grooving is caused when the metal does not fully fill the die or when a part of the die is corroded. Burning can occur when the temperatures used to forge the metal are too high.
In order to prevent these surface defects from occurring, proper die and temperature maintenance is essential. The die should be regularly inspected and maintained to ensure it is not corroded or misaligned. The temperature of the forge should also be closely monitored to prevent overheating of the metal.
Inclusion Defects
Inclusion defects can occur when small particles of material are trapped in the metal during the forging process. These particles can range in size from microscopic to visible by the naked eye. They can be formed due to a number of causes including corrosion, dirt, or improper alloying of the material. These particles can have a drastic effect on the strength and integrity of the metal, as they can act as stress raisers and lead to premature failure.
The best way to prevent inclusion defects is to use only clean, high-quality material for the forging process. Additionally, any corrosive substances or dirt should be removed from the forging area to reduce the likelihood of contamination.
Conclusion
In conclusion, improper forging can lead to a number of defects in the finished product. Cracks, surface defects, and inclusion defects are among the most common types of defects. It is essential that proper technique and maintenance is employed to reduce the likelihood of these defects occurring. Additionally, any defects should be addressed and repaired promptly in order to prevent any further damage to the metal.
