Aluminum is one of the most used materials in the world, and aluminum components are found in all walks of life. This includes aerospace components and parts for construction, process equipment, as well as electrical components and automotive manufacturing.
There are several different ways to mold parts and assemblies out of aluminum. One of the most cost-effective methods is to use one of the many options available in the aluminum forging process.
Aluminum forgings rely on applying very high levels of pressure and force to the alloy. The aluminum raw material is heated to a specific temperature to make it more ductile, but does not melt the material. This heat and application of pressure or hammering type of force results in a final part that is strong, lightweight and extremely durable.
Open Die Forging: This aluminum forging process is typically used for large components. These parts are usually produced by hand-controlled forging operated by experienced professionals.
Precision Forging: In this process, the aluminum is impacted using gravity through a precision-cut die. This can be done in one go or by using incremental forming dies, allowing the final part to meet very tight tolerances. This can be used to create simple or complex shapes.
Pressure forging: Unlike the fast, high-impact equipment common in precision forging that pushes aluminum through a die, pressure forging uses slow, steady pressure to push aluminum into a given die. It's important to remember that the term slow refers to seconds per part, not several parts per second.
There are other options for the forging process. Swaging uses the force on tubular aluminum to reduce the diameter, and roll forging is used to flatten part of the stock into the desired final shape.