Demand for aluminum forgings has increased in the automotive and aerospace industries due to their light weight and high strength. Aluminum forgings are used extensively in these industries to make vehicles and aircraft lighter, safer, and more fuel efficient. The main factors that influence aluminum forging are the heating temperature of the dies and aluminum stock, which must be carefully controlled within a narrow range to ensure successful forging. Lubricants are also important to control metal flow and reduce forging loads. Common aluminum alloys used in forging include 6061 due to its strength and wide temperature forging range.

3.  Demand for aluminum forging products especially in
automotive and aerospace industry has been
increased in recent years due to their lightness,
strength and Aluminum forging products are used in
automotive and aerospace industry for the
necessity to make modern vehicles lighter, safer and
more environmental friendly. The automotive
industry is one of the major users of aluminum forged
parts since low-fuel-consumption cars have been
demanded for the economy in recent years

4.  high strength and low weight
 good corrosion resistance (for most aluminium
alloys)
 the fibre (grain) structure can be arranged to
correspond to the main loading direction leading to
high strength and fatigue properties

5.  Used primarily for structural components such as
the intake of gas turbine engines.
 Used in helicopters, piston-engine planes,
commercial jets and supersonic military aircraft.
Many aircrafts contain more than 450 structural
forgings as well as hundreds of forged engine
parts.
 Used as housings, casings, linkages for a variety of
mechanical systems
 Used in automotive applications where commonly
shock and stress are critical such as: Connecting
rods, pistons, crankshaft, gears, axle beams,
steering arms, wheel spindles.

6.  Forgeability represents the ability of a
metal to be deformed without failure,
regardless of the magnitude of load and
stresses required for deformation.
Although all aluminum alloys have good
forgeability from the standpoint of
ductility, the energy and load
requirements vary appreciably with
composition

8.  the heating of dies plays very important role in
forging operation.
 Heating of dies can successfully raise the level of
metal plasticity and flow properties .
 decrease the forging pressure on the material.
 high dimension of accuracy .

9.  The metal temperature and the die temperature
are critical factors in aluminum forging process.,
aluminum forging has a very narrow temperature
range and control of the temperature at those
ranges is important for the successful forging
operation

10.  Gas-fired furnaces are the most widely used for
heating aluminum for forging, mainly because gas
is widely available and is usually the least
expensive source of heat. Furnace design and
construction necessarily vary with the requirements
of the operation.
 Oil-fired furnaces
 Electric furnaces

11.  Heating time for aluminum alloys varies, depending on the
section thickness of the stock and the furnace
capabilities.However, in general, because of the increased
thermal conductivity of aluminum alloys, the required heating
times are shorter than with other forged materials

12.  Lubricants and lubrication of dies are
very important in forging operations.
There are several advantages :
 Metal flow can be controlled and
improved.
 Lubrication decreases the die friction
and helps die filling.
 Lubricants are used to reduce forging
loads.

13.  Aluminum products should be cleaned as soon as possible
after forging. In general, the following type of treatment will
remove oxide and lubricant residue and produce smooth
surface with a natural luster
 Immerse in a 4 to 8 weight percent aqueous solution of NAOH
at 71 °C for 0.5 to 5 minutes.
 Rinse in 77 °C water for same length of time.
 Immerse in aqueous solution of nitric acid, 10 percent by
volume, at a temperature of 88 °C of higher to remove black
deposit.
 Rinse in hot water.

16.  In general, most aluminum alloys are
forged at about 55 o C below the
melting point temperature, but with
dependence on the speed and on the
total amount of deformation .

17.  Aluminum alloy 6061 is one of the most important
aluminum alloy used in different application areas
such as aircraft fittings, couplings, marines fittings,
hydraulic pistons and valves
 chosen as 6061 which is presented in material
database of SfForming for the temperature range
of 250-500 oC. Yield stress-strain rate curves of
aluminum alloy 6061-0 are given

22. Figure 6.4 Effective Stress Distribution for the Upsetting Operation of
Aluminum Alloy 6061 at 200 C

24. Figure 6.5 Effective Stress Distribution for the Finish Operation of
Aluminum
Alloy 6061 at 200 oC

25. Figure 6.6 Temperature Distribution for Upsetting Operation of
Aluminum
Alloy 6061 at 200 oC

26. Figure 6.7 Temperature Distribution for Finish Operation of Aluminum
Alloy
6061 at 200 oC

27. END