Introduction
Forging, especially high strength forging aluminum alloy, is of increasing importance and application in the automotive industry for making light weight and high strength components. Among the metal materials for forging operations in the automotive industry, aluminum alloys, with their light weight and high strength characteristics, are gaining greater appreciation. The aim of this study was to analyze the effects of high strength forging on the microstructure, mechanical properties and fatigue life of aluminum alloys.
Aluminum alloys are increasingly used in the automotive industry due to their light weight and high strength. The high strength forging process of aluminum alloys involves high forging temperatures and high forging forces in order to achieve the desired high strength. High forging temperatures help in improving the flow behavior of the aluminum alloys and also help in improving their fatigue life. Higher forging forces, on the other hand, help in improving their mechanical properties and tensile strength.
Experimental Procedure
A series of forging experiments were conducted in order to analyze the effects of high strength forging on the microstructure, mechanical properties and fatigue life of an aluminum alloy containing 6.5 wt. % Mg, 1.5 wt. % Si, 0.2 wt. % Fe and 0.1 wt. % Cu. The aluminum alloy was heated to a temperature of 600°C in a heating furnace and allowed to cool down to room temperature. The aluminum alloy was then placed in a forging press and subjected to a series of high forging forces. The forging force was increased stepwise from 50 to 300 kN in order to analyze the effects of the forging process on the microstructure, mechanical properties and fatigue life of the aluminum alloy.
Results and Discussion
The results of the experiments showed that the application of high forging forces produced a fine and homogeneous microstructure in the aluminum alloy. The microstructure consisted of a homogeneous distribution of fine grains and particles. The mechanical properties of the aluminum alloy were improved significantly due to the high strength forging. The tensile strength of the aluminum alloy was increased from 240 MPa to 300 MPa and the fatigue limit was increased from 120 MPa to 170 MPa. The fatigue life of the aluminum alloy was improved by almost 48 % due to the high strength forging process.
Conclusion
In conclusion, it can be seen that high strength forging is an effective way of improving the microstructure, mechanical properties and fatigue life of aluminum alloys. The experiments showed that high forging forces were able to produce a fine and homogeneous microstructure in the aluminum alloy and also improve the mechanical properties and fatigue life. In addition, the fatigue life of the aluminum alloy was improved significantly due to the high strength forging. Thus, it can be concluded that high strength forging of aluminum alloys is an effective method for improving the properties of aluminum alloys for automotive applications.
