Magnesium alloy forging defects
Forging is a process used to produce certain parts through compressing, shaping and forming metals at high temperatures. Magnesium is a light weight and relatively soft metal that is used in many common applications. Forging is a popular technique for producing magnesium alloy components, but there are potential defects that can arise during the forging process. Knowing the common magnesium alloy forging defects and how to prevent them can reduce the risk of costly repair or replacement.
One common magnesium alloy forging defect is a lack of consistent geometrical features. Defects can occur due to uneven heating and other variables that cause variations in shape and size of the components. Machines used for magnesium alloy forging must be properly calibrated and maintained to ensure that components are produced consistently. The dies used for forging must also be properly prepared and inspected before use.
The second common magnesium alloy forging defect is porosity. Porosity can occur due to the presence of an inadequate amount of lubricant, or due to a difference between the rate of cooling and the rate of plastic deformation. Porosity reduces the strength of forged components, creating a risk of failure in the part. To reduce the risk of porosity, proper lubrication should be used, and the temperature of the forging should be monitored closely.
Another common magnesium alloy forging defect is misalignment. Mismatched dimensions can occur due to inaccuracies when setting up the machine, or due to inadequate clamping force. Uneven clamping force can also create voids and affect the shape of the component. To prevent misalignment, the machine must be set up properly and the clamping force must be uniform and consistent.
The fourth common magnesium alloy forging defect is cosmetic blemishes. Blemishes can occur due to inadequate surface preparation, or due to insufficient force during the forging process. To prevent blemishes, the surface should be pre-treated to remove any oils or contaminants. The force used during the forging must also be monitored closely to ensure it is applied properly.
The fifth common magnesium alloy forging defect is cracking. Cracking can occur due to unequal heating or cooling, or due to incorrect grain size. Uneven heating can cause grains to become distorted, and incorrect grain size can lead to increased stress and brittleness. To prevent cracking, the temperature of the forging should be properly monitored and the grain size of the metal should be consistent.
In conclusion, forging defects in magnesium alloy components can be avoided if the components are properly produced and inspected. The key is to ensure that the machinery is properly calibrated and maintained, and that the dies are properly prepared and inspected. The temperature of the forging must also be monitored closely to ensure that components have adequate lubrication and consistent grain size. Finally, the forging force must be applied with uniform pressure to avoid misalignment and blemishes. With proper production processes, magnesium alloy components can be produced to specification and without defects.
