Forging improves the quality of magnesium alloy die castings.
magnesium alloy is emerging as a "new aluminum alloy" because of its light weight. Thus, hot chamber magnesium alloy die castings are becoming popular in the manufacturing industry. The process of producing precision magnesium alloy parts requires a series of configurations, but die-casting equipment may be important, especially the S-shaped elbow that transmits molten magnesium alloy to the mold
sloan ind. since the release of version a in January 1971, industries, Inc. (wood Dale, Illi, such as higher permeability, better heat resistance, excellent mechanical properties, nois) is a precision measuring factory that supplies vulnerable parts for the magnesium alloy die-casting industry. The essence of displacement measurement is to measure displacement with a standard ruler with a grating spacing of 1. The company has found that using S-bend forgings can obtain better processability and part quality than S-bend castings. Together with Scott Forge (spring grove, Illinois), the company began to supply S-shaped elbow forgings for the manufacturing industry, and they are very competitive due to the implementation of innovative projects
"it is critical for us to supply high-quality products to support our growing magnesium alloy die casting industry, which better reflects the characteristics of new material industry customers," said Henry slowinski, President of Sloan industries. "Magnesium alloy is becoming the preferred material in high-tech, aviation and other industries because of its strength to weight ratio, dimensional stability and recyclability," he noted. "It's not as brittle as aluminum alloy."
this forged square head combined with the slender shaft generation
shows the original two in one design
hot chamber magnesium alloy die casting process uses S-shaped elbow and piston to inject molten magnesium alloy into the mold. The S-shaped elbow is immersed in molten magnesium alloy, and the cavity of the S-shaped elbow is filled with metal through the filling hole on the side. The piston pushes the molten metal to fall from the top, supplies the metal through the vertical feeding hole and nozzle of the S-shaped elbow and injects it into the mold without being exposed to the outside environment. When the metal solidifies in the mold cavity, the mold opens and the parts are ejected. At the same time, the piston retracts to the initial position higher than the filling hole. The mold closes again, and the S-bend is filled with molten metal and ready for the next injection
sloan Industries supplies s-bends with specifications ranging from 80 tons to 528 tons. These S-shaped bends must be able to withstand temperatures of 1300 degrees, and they must be able to withstand magnesium alloys with good wear resistance. Until recently, the S-bend provided by the company was made of sand castings, but the defects in the S-bend castings led to cracking, sand holes and processing problems
"this specification is called DIN 1.2888 cast steel. It will withstand the requirements of chemical and high-temperature working environment, but it is expensive and difficult to cast." Adam niedospial, vice president of the company, said. "The inconsistency and shrinkage cavity of S-shaped elbow castings cause processing delays. Up to 40% of castings have to be discarded before being supplied to customers, which is very wasteful and affects our timely delivery."
this rough machined 2-in-1 forging is ready to be sawn in half
the company is looking for alternatives to castings, so it considers using solid bars to manufacture S-shaped bends. However, this approach will require too much material and processing, and the result is that the associated costs will make it impossible for the company to remain competitive
forging is an attractive alternative to S-shaped elbow castings. In the forging process, a solid billet is formed on an open forging die. This strengthens the center of the blank and is said to eliminate loose holes
the company has cooperated with Scot forge, an open die and roll sleeve forging company, to produce the aforementioned parts. Scot forge uses presses ranging from 750 tons to 5500 tons, and it can produce shaft parts with any combination of circular (cylindrical), square, flat or polygonal sizes
scot forge provides a "proactive partnership" program written with machinery plants and metal parts buyers to optimize part quality while minimizing waste and reducing costs. According to the company, the main task of this plan, led by an experienced metallurgist, is to find ways to use the forging process to produce cheap, high-quality parts. It also intends to identify and eliminate unnecessary processes and improve the strength of parts, usually combining multiple parts into a "stronger" part
in this case, the shape of the S-shaped elbow requires a slender shaft plus a square head. The sales engineers of Scot forge are confident that they can forge this slender shaft with square head and propose an economical "two in one" solution. "The sales team paid attention to the overall dimensions; they realized that the production of two S-shaped bends by forging at one time would reduce the cost," explained Tim peglow of Scot forge. "We began to put a billet on a hydraulic press equipped with an open forging die, make a square center part, and then hit each end with a slotting hammer to make it smaller. Then we processed it into the shape of a round journal." Mr. peglow added, "forging S-shaped bends in this way makes processing and handling easier."
"they helped us find an alternative to DIN 1.2888 special cast steel," Mr. slowinski said. "The substitute must be able to withstand the wear resistance of magnesium alloy. The metallurgical experts of the company worked with us and found a stainless steel based alloy with good strength that can replace the original specification.
" Scot forge's technical expertise and the concept of two in one have eliminated the problem of porosity, "he continued. "We can now provide our customers with a reliable product with a longer service life." (end)
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