The Potential of Cast Stock for the Forging of Aluminum Components within the Automotive Industry

Abstract

In the automotive industry, there is a drive to reduce environmental impact, energy consumption, and costs related to the manufacturing of forged aluminum suspension components. The replacement of extruded stock with cast forging stock is one option that offers substantial potential for such savings. The casting technology, low-pressure casting (LPC), allows for production of high-quality cast forging stock with minimal surface segregation and smaller diameters than those achieved with traditional casting technologies. This study is a proof-of-principle, conducted to directly compare the microstructure and mechanical properties of LPC and extruded material after forging, through both generic and full-scale industrial forging trials. The results show the advantages of the cast material, including higher robustness against surface grain growth after forging and a positive correlation between mechanical properties, both strength and ductility and the introduction of plastic deformation. Overall, the work demonstrates how forged aluminum components produced from LPC forging stock can achieve mechanical properties and performance, on par with extruded forging stock, showcasing industrial relevance through the production of a safety-critical automotive component.