Liquid mold Forging Composite
Liquid mold forging (LFD) is a metal forming process that combines conventional forging and casting. In the process, a molten metal is poured into the liquid mold, and then the liquid mold is rapidly cooled in order to form and solidify the shape of the desired part. Then, this liquid mold is placed into a conventional forging press and forged to shape and desired properties.
The process combines two distinct metallurgical processes into one operation and produces custom parts with complex geometries with excellent material properties. The primary benefit of the process is parts can be made more quickly than with traditional forging methods. Additionally, the process has the capability to form net shape parts, which helps to reduce scrap material causing cost savings.
LFD process is considered to be a greener process due to the use of cold forming and a die-less forming process. The combination of cold forming and die-less forming creates a greener process that has reduced the amount of energy used to produce parts, leading to a more efficient process with fewer emissions.
The LFD process not only provides a greener process, but also allows for complex geometries with very tight tolerances and high-strength characteristics. Typical applications for this process include aerospace parts, medical implantable missiles and gun barrels. Examples of parts that are often produced using the LFD process include: turbine blades, nozzle bodies, compressor blades, ejector assemblies, guide valves and manifold blocks.
Due to LFDs high-performance properties, the process is often used in the production of high-performance components. For example, the LFD process is often used to create highly complex and intricate parts for the aerospace industry. The process is also used to fabricate components for sports and recreational equipment such as helmets, baseball bats, and ski poles.
Despite its numerous benefits, there are some disadvantages associated with LFD. The LFD process is limited in terms of the alloys that can be used, as the molten metal needs to flow freely into the liquid mold. Furthermore, the process is often more expensive than traditional forging. Finally, the process can be prone to flaws, such as porosity, shrinkage and seams, due to the liquid mold cooling process.
Despite these drawbacks, LFD is becoming increasingly popular due to its numerous benefits. As industries become increasingly aware of the process properties and its ability to quickly create custom parts with excellent material properties, the process will become even more common in the future.
