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29 Apr, 2025
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Insight of Aluminum Forging Process You Should Know
Aluminum forging is a manufacturing process in which aluminum alloy is shaped under high pressure to form strong, lightweight components. Due to its excellent strength-to-weight ratio, corrosion resistance, and thermal conductivity, aluminum is widely used in aerospace, automotive, defense, and medical industries. The process involves heating the aluminum billet to a specific temperature (not melting point) and pressing it into dies that define the final shape. This results in high structural integrity, improved grain structure, and tight dimensional tolerances.
Type Of Aluminum & Alloy
In aluminum forging, several aluminum alloys are used depending on the application. Here are the most common types:
🔹 1. 2xxx Series (Al-Cu Alloys)
High strength, used in aerospace & defense.
Example: 2024-T4
🔹 2. 6xxx Series (Al-Mg-Si Alloys)
Good strength, corrosion resistance & weldability.
Widely used in automotive and structural parts.
Example: 6061, 6082
🔹 3. 7xxx Series (Al-Zn Alloys)
Extremely high strength, often used in aerospace.
Example: 7075-T6
🔹 4. 5xxx Series (Al-Mg Alloys)
Excellent corrosion resistance, used in marine & transport.
Example: 5083, 5052
Forging VS Casting:
Forged parts had a 26% higher breaking load than the same cast parts.
Forged parts had a 37% higher weary strength resulting in a much longer lifespan than cast parts.
The forged parts have a 58% reduction in area when pulled to failure, compared to 6% reduction for cast parts. Which means forge parts can tolerate way more deformation before said part fails to operate as intended than cast parts.
How to Do Aluminum Forging?
Design your product
Select and Acquire Material of Choice
Mold Production
Test Mold (Forge Samples with Newly made Mold and Analyze Sample)