Aluminum Alloy Forging Heating Process
Aluminum forging is the reshaping process of aluminum alloy components through the use of heat and pressure. Heat is used to soften aluminum alloy material, causing it to flow more freely, and pressure is then used to complete the forming process. Forging is common as it allows components to be formed with much complexity and in much higher strength than machined parts. Some alloys may require very specific heating processes to achieve proper forging temperatures during the process, and aluminum alloy is no exception.
Aluminum alloy, like steel, is an alloy of two elements: aluminum and one or more metal components. Alloying metals can cause different properties to be expressed in the metal, permitting it to be used in a wider variety of applications. Different alloys will have different melting temperatures, higher or lower, than pure aluminum. Because aluminum melts at around 660 degrees Celsius (1,220 degrees Fahrenheit), a special heating process must be applied when forging aluminum alloy.
Aluminum alloy forging is typically done with resistance heating or induction heating. Resistance heating involves passing an electric current through resistance wire embedded in the aluminum alloy, which causes it to heat up. Induction heating uses a magnetic field that passes through one of the aluminum-alloy components, and creates an electrical current within it. This current then causes the component to heat up.
The typical heating process begins with the aluminum alloy material being heated to a few hundred degrees Celsius below the melting point, allowing the metal to deform without actually liquefying. The heating pattern must be carefully monitored and maintained throughout the entire process, as the metal will cool off quickly and may not deform correctly. In many cases, a heat-treating oven is used to ensure that the forging temperature remains consistent.
Once forging is complete, the aluminum alloy component may need to be cooled off and/or hardened to reach its full strength potential. After the components have cooled, a final heat treatment may be done, either hot or cold, in order to further strengthen the aluminum alloy and give it desired characteristics. Hot treatments usually involve heating the component and submerging it in a quenching solution, such as water, oil, or gas, whereas cold treatments involve cooling the components slowly.
Aluminum alloy forging can be a very useful method of creating strong, complex components. Proper heating is essential to achieve desired results and to ensure the component has reached the desired strength and other characteristics. With careful monitoring of temperatures and controlled cooling, components created through aluminum alloy forging can provide added strength and durability that other methods cannot provide.
