Aluminum Precision Products: Aluminum Forgings?

Forging mystery? Strong, light parts needed? Wrong process means weak, costly components. Understand aluminum forgings¹ for superior results and product integrity.

Aluminum forgings are components made by shaping aluminum alloy under immense pressure. This process enhances strength, grain structure, and fatigue resistance, ideal for critical applications.

At SWA Forging, our slogan "Master Southwest Aluminum Right" guides us. We specialize in large-diameter forged rings and discs. Our mission extends to sharing knowledge. Many clients, from traders to machining plant managers, ask about forgings. Understanding this process is key to appreciating why forged aluminum parts are often superior for demanding applications. Let's explore this.

What are aluminum forgings?

What are aluminum forgings? Unclear about this process? This lack of clarity can lead to choosing weaker, less reliable manufacturing methods for your parts.

Aluminum forgings are strong, durable metal parts created by heating aluminum billets and shaping them with powerful compressive forces, like hammering or pressing, into desired forms.

Aluminum forgings are essentially high-strength aluminum parts. We make them by taking a piece of aluminum alloy, usually a billet or ingot, and heating it up. Then, we use powerful machines to press or hammer it into a specific shape. This shaping happens inside dies, which are like molds made of very hard steel.

The immense pressure does something special to the aluminum. It refines the internal grain structure of the metal. Think of it like kneading dough, but with much more force. This makes the final part much stronger and more durable than if it were made by other methods, like casting. I remember a client who was using cast aluminum parts for a critical component in their machinery. They kept experiencing failures. After we supplied them with forged aluminum replacements, the problem disappeared. The forged parts could handle the stress much better.
There are different ways to forge. Open-die forging, which we use a lot for our large rings and discs at SWA Forging, allows us to make very large parts and offers flexibility. Closed-die forging, or impression-die forging, uses dies that completely enclose the workpiece. This is great for making more complex shapes with high precision, often needing less machining later. This is called a near-net shape. It saves material and time for machining plants.

What is the difference between aluminium and forged aluminium?

Aluminum vs. forged aluminum – confused? Using standard aluminum where forged is needed causes failures. Understand the crucial differences for optimal material performance.

"Aluminum" is the base metal. "Forged aluminum" refers to aluminum alloy that has undergone the forging process, significantly enhancing its mechanical properties like strength and toughness.

When we say "aluminum," we are usually talking about the basic metal itself or an aluminum alloy in a general state. It could be a sheet, a bar from an extrusion, or a cast part. "Forged aluminum," however, is aluminum alloy that has been through a specific manufacturing process – forging. This process dramatically changes its properties for the better.

The biggest difference lies in the internal structure. Standard aluminum, especially if it's cast, might have a random grain structure. It might also have tiny internal voids or porosity. Forging changes all that. The intense pressure closes any voids. It also refines the grain size and makes the grains align with the shape of the part. This aligned, fine-grain structure is what gives forged aluminum its superior strength and resistance to impact and fatigue.

I often explain this to customers, especially traders who need to relay this information accurately. Think of it like wood. A standard piece of wood has its grain. If you try to bend it against the grain, it might snap. But if the grain flows with the shape of a curve, it's much stronger. Forging does something similar for aluminum. It makes the material "flow" with the part's shape, making it incredibly robust. This is why our forged discs and rings at SWA Forging are so sought after for demanding applications.

This transformation is why forged aluminum is a premium choice for applications where failure is not an option.

What is the best aluminum alloy for forging?

Best forging alloy? Choosing the wrong alloy leads to poor forgeability or parts that don't perform. Selecting the right one is key to success.

Commonly forged alloys include 2014, 2618, 6061, 7075, and 7050. The "best" depends on desired strength, corrosion resistance, temperature performance, and application-specific needs.

There is no single "best" aluminum alloy for forging. The ideal choice really depends on what the final part needs to do. As a supplier, at SWA Forging, we guide our customers through this selection. Machining plants, for instance, will have very different needs depending on whether they are making parts for aerospace or general machinery.
Some alloys are very popular for forging because they offer a great combination of properties and are easy to work with.

• 6061 aluminum alloy²: This is a real workhorse. It has good strength, excellent corrosion resistance, and it forges very well. We see it used in a huge range of applications, from automotive parts to bicycle frames and structural components. It's often a go-to for many of our custom forged ring and disc orders.
• 2xxx series alloys (like 2014 or 2618): These are known for their high strength. Alloy 2618 is particularly good at holding its strength at higher temperatures, so it's used in things like aircraft engine pistons.
• 7xxx series alloys (like 7075 or 7050): These offer the highest strength among aluminum alloys. You will find them in aerospace applications, like aircraft structures, where maximum strength-to-weight ratio is critical. They can be a bit more challenging to forge and might be more susceptible to stress corrosion cracking if not treated properly.
  I recall a project with a machining plant. They needed a high-strength part but were also concerned about machinability. We looked at both a 7xxx series and a high-strength 2xxx series. After discussing the final application's environment, a specific temper of a 2xxx alloy proved to be the better balance.

Choosing correctly means considering strength, toughness, corrosion resistance³, temperature exposure, and of course, cost.

What is the difference between extrusion and forging aluminum?

Extrusion or forging? Choosing incorrectly means parts aren't optimized for shape, strength, or cost. Understanding these distinct processes guides better design decisions.

Extrusion pushes aluminum through a die to create linear profiles. Forging shapes aluminum with compressive force, often into more complex, discrete parts with superior strength.

Extrusion and forging are two very different ways to shape aluminum. Both are important, but they produce parts with different characteristics, suitable for different jobs. It's crucial for our customers, whether traders advising their clients or machining plants sourcing materials, to know the difference.
Extrusion is like squeezing toothpaste from a tube. We heat an aluminum billet and push it through a die with a specific cross-sectional shape. This process is excellent for creating long, continuous shapes with consistent profiles. Think of window frames, door tracks, heat sinks, or architectural beams. The grain structure in an extruded part is aligned along the length of the extrusion. It's a very cost-effective way to produce these types of linear components.
Forging, on the other hand, shapes a discrete piece of aluminum. We use immense pressure or impact to force the metal into a die cavity. This creates individual parts, not continuous lengths. The big advantage of forging, as we've discussed, is the superior mechanical properties. The forging process refines the grain structure and aligns it with the contours of the part. This gives much higher strength, toughness, and fatigue resistance compared to most extrusions.
I remember a customer who was considering using a heavy-duty extruded section for a structural connector. After we discussed the loads and potential for impact, they realized a forging would be far more reliable, even if the initial part cost was a bit higher. The long-term integrity was worth it. At SWA Forging, our specialization in forged rings and discs comes from the need for these superior properties in critical applications.

So, if you need a long, simple shape, extrusion is often great. If you need a strong, durable, and reliable discrete part, especially for high-stress situations, forging is usually the way to go.

Conclusion

Aluminum forgings offer superior strength and reliability for critical parts. Understanding them helps you choose the best manufacturing path for your specific aluminum needs.