Q&A
Basic concept of forging:
Purpose: To change the shape of the metal and enhance its strength and toughness.
Principle: By applying plastic deformation, forging breaks internal casting defects, refines the grain structure, and improves the mechanical properties of the material.
✅Common Aluminum Forging Alloy Types
- 2xxx Series: Aluminum-Copper Alloys (Al-Cu)
Representative grades: 2014, 2024
- High strength
- Excellent fatigue resistance
- Good machinability
- Applications: Aerospace structural components, connecting rods, high-load mechanical parts
- 5xxx Series: Aluminum-Magnesium Alloys (Al-Mg)
Representative grades: 5083, 5456
- Medium to high strength without heat treatment
- Excellent corrosion resistance
- Good formability
- Applications: Marine components, corrosion-resistant industrial parts
- 6xxx Series: Aluminum-Magnesium-Silicon Alloys (Al-Mg-Si)
Representative grades: 6061, 6082
- Moderate strength with good forgeability
- Stable performance after heat treatment (T6)
- Good weldability
- Applications: Automotive and motorcycle parts, bicycle components, structural parts
- 7xxx Series: Aluminum-Zinc-Magnesium Alloys (Al-Zn-Mg)
Representative grades: 7075, 7050
- Highest strength among aluminum alloys
- Can achieve ultra-high strength after heat treatment
- More difficult to forge but suitable for high-load components
- Applications: Aerospace, military-grade parts, high-stress connecting rods and joints
- Aluminum billets
- Round bars
- Extruded stock
- Aluminum slug-----Commonly used for cold forging
- Required strength, stiffness, and toughness
- Whether welding is needed
- Exposure to corrosion or high temperature
- Manufacturing method (hot forging / cold forging)
- Cost and material availability
- Forging Diagram
- Casting Diagram
- Comparison Table
| Category | Forging | Casting |
| Definition | Forging is a manufacturing process that shapes metal using localized compressive forces. | Casting involves heating metal until it becomes molten and pouring it into a mold to form various shapes. |
| Material Form | Solid metal (e.g., bars, billets, plates, etc.) | Liquid metal (e.g., iron sand, steel sand, etc.) |
| Compressive & Fatigue Strength | Higher | Lower |
| Temperature | Approx. 950°–1250°C | Approx. 1360°–1420°C |
| Shape & Size Capability | Forging has limitations in producing complex metal shapes. | Different casting methods can produce a wide variety of metal shapes. |
| Tolerance | Lower | Higher |
| Labor Requirement | Forging typically requires more manual labor than casting. | Casting generally requires less manual labor than forging. |