AN INNOVATIVE PROCESS

Liquid Forging

A unique technique of fusion of light alloys which involves the application of a very high pressure on the material in the liquid state during the solidification phase.

"Quality, Versatility, Competitiveness"

Our services- this technology Is especially suitable for the production of:

Suspension components, parts of braking systems, mechanical supports, etc. (automotive sector).

Steering bases, rocker arms, engine mounts, connecting rods, etc. (motorcycle sector).

Products in aluminum alloys obtained with other casting techniques.

FEATURE

Comparison of forging processes

Liquid Forging Process

1| MELTING

  • Melting Furnace
  • Degas
  • Filter

Conventional Extrusion Process

1| MELTING

  • Melting Furnace
  • Degas
  • Filter

CASTING

2| DC Cast
3| Ultrasonic inspection
4| Homogenization

5| EXTRUSION

  • Scalping
  • Preheat
  • Extrusion
  • Press

6| Straighten & Cut

FORGING

The complete escape of the air contained in the mold is ensured by the slow entry of the metal and by specially made "airs".

The compaction of the metal during solidification allows the recovery of the desired shape considering the transition from the liquid state to the solid state.

The density of the product is superior to any traditional casting process (gravity or diecasting) and equivalent to forging.

The completely automatic production cycle is guaranteed by the technical solutions adopted on the machine lay-out.

Cycle time much shorter than Squeeze Casting (ratio 1: 2.5)

QUALITY

Quality, Versability, High competitiveness!

  • • Structural integrity.
  • • Absence of porosity
  • • Tighter dimensional tolerances than hot forged.
  • • Possibility to carry out heat treatments.
  • • Excellent micro-structure, for rapid solification following forced cooling of the mold.
  • • Suitable for all types of light alloys, including magnesium (6082, 7075, 2014,0 A356, AlSi4.5, AlSi9, Magsimal, Silagont ...).
  • • Possibility of producing parts with inserts.
  • • Possibility of obtaining complex geometries.
  • • Possibility of producing pieces weighing from 40g up to 10 kg.
  • • THERE IS NO SCRAP!
  • • The right amount of liquid metal becomes the piece.
  • • Possibility of creating multi-figure molds with significant reductions in cycle time.
  • • Possibility of having different figures in the same mold.
  • • Cost positioned between shell casting and diecasting.

SAVINGS

Quality, Versability, High competitiveness!

The cost of Liquid Forging is lower than that of gravity casting, offering better quality and mechanical characteristics and higher productivity.

The comparison shows the cost in euros of the part made for Volvo in the various technologies. It is necessary to keep in mind the higher costs for die casting, gravity and low pressure due to 100% impregnation, or a variable waste from 6 to 20%.

ANALYSIS

Percentage of porosity of the different technologies.

POROSITY

Percentage of porosity of the different technologies.

ANALYSIS

The radioscopic images illustrate the compactness of the Volvo transfer case, the absence of porosity, microporosity, blowholes, cracks and crystallizations (characteristics common to entire production batches).

MICRMICROSCOPE EXAMINATION

The microstructure at the surface of the jet is very fine, due to the very fast cooling of the liquid.

The interdendritic eutectic solidification microstructure is finely modified.

The core structure has a high dendritism, with average DAS values of about 18 µm, a rapid cooling index.

MECHANICAL PROPERTIES

The hardness of the material is equal to 64.5 ÷ 67.5 HBW5 / 250, consistent with the lack of heat treatment of the alloy. From the casting, 3 cylindrical specimens (L0 = 5xdiameter) were taken, subjected to tensile tests according to the house standard.

The material is characterized by a minimum elongation value comparable to that expected for the same fussa alloy in semisolid (thixoforming), according to tab. 53231. 5 Charpy resilience tubes without notch were also made from the cat; the test (performed according to table 50130) produced values equal to KC = 43 ÷ 52 J / cm2, high for an aluminum alloy casting.

PATENT