Aluminum and its alloys are one of the most widely used non-ferrous metals today, and its output is second only to steel. The amount of aluminum in the Earth's crust is about 8.13%, which is more than twice that of iron and even more than all other non-ferrous metals combined. This abundance of resources makes aluminum alloys ideal for lightweight applications. The density of aluminum alloys is only one-third that of steel (2.7 g/cm³ for aluminum alloys and 7.85 g/cm³ for steel), which gives them a significant advantage in areas where weight reduction is required.
Due to its high strength, stiffness and fatigue resistance, aluminum forgings are widely used in many industries such as machinery, aviation, automobiles, railway vehicles, ships and sea vessels, buildings and Bridges, chemicals and power generation. Replacing steel forgings with aluminum forgings can not only significantly reduce the weight of mechanical products, but also enhance the stability of the structure. This is particularly important in the aerospace, aerospace and defense sector, where the proportion of aluminum forgings in aircraft components can reach 15 to 50 percent.
As global automakers strive to reduce fuel consumption and environmental impact, aluminum alloys are increasingly being used to replace steel in order to reduce vehicle weight. For example, Japan produced 30,459 tons of aluminum forgings in 2009, accounting for 2.7% of its total closed die forgings. According to Honda's 2004 strategy report, each vehicle contains an average of 200 kilograms of aluminum parts, of which 40 kilograms are aluminum forgings. The application trend of aluminum forgings in automobiles is growing, especially in axle and chassis components such as wheels and control arms. From 1985 to 2002, the share of aluminum forgings in the global total forgings increased from 0.5% to 15%, a shift driven by the need to improve energy efficiency and environmental sustainability.
Demand for aluminum forgings is expected to continue to grow as the automotive industry moves toward lightweight designs to meet consumer demand for comfortable rides and better handling. A 10% reduction in vehicle weight can reduce fuel consumption by 8% to 10%. In the United States, aluminum alloy accounts for 36.3% of the weight of cars, while in Europe and Japan, the proportion is more than 15%. The lightweight construction of high-speed trains also drives the demand for aluminum parts, such as the 7075 high-strength aluminum forgings produced by CFS Forge.
Forging ability refers to the ability of aluminum alloy to fill the mold under the action of external force. High forging ability means that blanks can easily fill mold grooves. Ductility is measured by the plasticity and deformation resistance of the material, and higher plasticity and lower deformation resistance mean better ductility and processability.
Malleability is a key index of metal plastic workability, which not only depends on the inherent quality of aluminum alloy such as plasticity and strength limits, but also depends on the processing conditions to a large extent. This index reflects the ability of the metal to fill the mold and form complex shapes during plastic deformation. It is an important standard to evaluate the difficulty of metal plastic processing into high-quality parts. Good ductility means that aluminum alloy can achieve uniform plastic flow under low deformation resistance, reduce defects during processing, and improve the yield and overall performance of parts.
The deformation resistance of aluminum alloy varies significantly with the composition. The 6000 series aluminum alloys have lower resistance to high temperature deformation, while the 7000 series alloys, such as Al-Zn-Mg-Cu, exhibit higher resistance. At room temperature, the deformation resistance of aluminum alloy is generally lower than that of carbon steel. However, at high temperatures, their deformation resistance can be lower than, equal to or higher than carbon steel. The deformation resistance of aluminum alloy is highly sensitive to temperature change, and the resistance increases rapidly with the decrease of temperature, faster than that of carbon steel. This sensitivity limits the forging temperature range of aluminum alloys and requires fast operation.
Plasticity is the ability of a metal to deform under external force without compromising its integrity. The plasticity of aluminum alloy in die forging determines its processing conditions. The friction coefficient between aluminum alloy and the die surface is 3 times that of steel, and its flow rate is only half, indicating strong adhesion, poor fluidity, and limited plasticity.
Due to the light weight, high strength and multi-functional characteristics of aluminum forgings, we expect the market demand for aluminum forgings to grow. CT Forging Company provides customized high-quality forged aluminum parts for a variety of industries. For enquiries relating to aluminium forgings, anodized aluminium forgings or machined aluminium forgings, please contact us. We are committed to meeting our customers' demand for high quality aluminum forgings through advanced forging technology and customized services.
