Titanium Alloy Forging Process

Titanium and titanium alloys have the advantages of low density, high specific strength, and good corrosion resistance, and are widely used in various fields. In order to use these materials better, researchers have done a lot of research on the titanium alloy forging process.

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Titanium Alloy Forging Process

The Main Process of Titanium Alloy Forging

Forging is a plastic forming process, that is, using the plasticity of metal to make the blank material obtain a certain shape and structural properties under the impact or pressure of the tool.

1. Free Forging

Free forging is generally carried out between two flat dies or molds without a cavity. The tools used in free forging are simple in shape, flexible, short in the manufacturing cycle, and low in cost. However, free forging has high labor intensity, difficult operation, low productivity, low forging quality, and large machining allowance. Therefore, it is only suitable for use when there are no special requirements for the performance of the parts and the number of parts is small.

2. Open Die Forging 

The blank is deformed between two molds with cavities, the forging is confined in the cavity, and the excess metal flows out from the narrow gap between the two molds, forming burrs around the forging. Under the resistance of the mold and surrounding burrs, the metal is forced to be pressed into the shape of the mold cavity.

3. Closed Die Forging

In the closed die forging process, no transverse burrs perpendicular to the direction of die movement are formed. The cavity of the closed forging die has two functions: one is for forming the blank, and the other is for guiding.

4. Extrusion Die Forging

It refers to using the extrusion method for die forging, which includes forward extrusion die forging and reverse extrusion die forging. Extrusion die forging can manufacture all kinds of hollow and solid parts and can obtain forgings with high geometrical precision and denser internal structure.

5. Multi-Directional Die Forging

Multi-directional die forging is performed on a multi-directional die forging machine. In multi-directional die forging, the slider acts alternately and jointly on the workpiece from the vertical and horizontal directions, and one or more perforation punches are used to make the metal flow outward from the center of the cavity to achieve the purpose of filling the cavity. 

6. Partial Die Forging

In order to forge large integral forgings on the existing hydraulic pressure, partial die forging methods, such as segment die forging, pad die forging, etc. can be used. The feature of the partial die forging method is to process the forging piece by piece, processing one part at a time, so the required equipment tonnage can be very small. Generally speaking, this method can be used to process extra-large forgings on medium hydraulic presses.

7. Isothermal Forging

Before forging, the mold is heated to the forging temperature of the blank, and the temperature of the mold and the blank remains the same throughout the forging process so that a large amount of deformation can be obtained under the action of a small deformation force. 

The forging process of titanium alloys is widely used in aviation and aerospace manufacturing (isothermal die forging process has been used in the production of engine parts and aircraft structural parts) and is increasingly welcomed by industrial sectors such as automobiles, electric power, and ships. 

Conclusion 

Businesses in many industries'including aerospace, marine shipbuilding, and military/defense'rely on titanium forging for various industrial and production-based uses. The metal's high demand is primarily thanks to the remarkable strength-to-density ratio of forged titanium alloys and the metal's significant anti-corrosive properties.

Both of these features result in a durable and reliable material that can work well on land, in the air, and even under the sea'all of which illustrate the versatility of titanium alloys. Forged titanium is beneficial because it allows you to get precision parts in custom dimensions for specialized applications that call for titanium's strength and versatility.

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Here's a quick overview of some processes used for forging titanium alloys, including the impact of different forging temperatures on the end product.

The Titanium Forging Process

Titanium forging is a set of specialized manufacturing processes used to create components from titanium alloys. The process that is ultimately used depends on the metallurgical properties of the starting material, plus the specific structure the forger is looking to create. Some of the processes include:

• Open Die Forging ' Blank titanium material is deformed and pressed into shape in the cavity between two molds. These molds do not completely encapsulate the material but instead provide a narrow gap through which excess material can flow out. When in the cavity, the titanium is repeatedly stamped until the desired shape is achieved.
• Closed Die Forging ' Also known as impression die forging, this method uses compression under high pressure to shape a heated titanium blank. The blank is covered either in full or in part by the dies, which move toward each other from top to bottom to achieve the required form.
• Free Forging ' Small and/or simple orders may be accomplished with free forging, a titanium forging method that is performed between two flat dies without an inner cavity. It is a relatively inexpensive and flexible method, but due to high labor requirements, it's not the most common way to forge large amounts of titanium metal.
• Isothermal Forging ' A process by which the starting material and the die are heated to an equal and highly controlled temperature to achieve high deformation rates with minimal pressure.

Other types of titanium alloy forging, such as multi-direction die forging, extrusion die forging, partial die forging, and rolled ring forging, rely on similarly unique alignments of heat, pressure, and die used to achieve desired shapes.

There are a number of benefits to titanium alloy forging, including:

• High Strength
• Corrosion Resistance
• Heat Resistance
• Biocompatibility
• Weldability

Additionally, there are a variety of different grades of titanium alloys that are used in the forging process, depending on the specific application requirements. When looking for titanium forging companies, ensure that the company you are interested in working with can forge titanium to the specifications you need.

Some of the most common grades include:

• 6-4: One of the most widely used titanium alloys in forging, 6-4 titanium is particularly popular in aerospace components.
• 6-2-4-2: Prized for its excellent creep resistance and strength at elevated temperatures, 6-2-4-2 titanium is utilized in components where high heat and stress are present.
• 6-2-4-6: Similar to 6-2-4-2 titanium, but with improved toughness and ductility.
• 3-2.5: Known for exceptional weldability and corrosion resistance, 3-2.5 alloy is often used in the medical industry for implants.

In short, titanium forging involves selecting the appropriate titanium alloy grade based on the application's requirements, and then subjecting the billet to a series of forging processes to create high-strength, corrosion-resistant, and heat-resistant components that possess numerous benefits for a variety of industries, depending on the alloy chosen.

Effects of The Forging Temperature

Can you forge titanium at any temperature? Technically, yes; however, the temperature used must be correct for the process and part.

Hot forging is more common than cold forging, though the latter can be cheaper and more environmentally friendly. Notably, lower temperatures (below degrees Fahrenheit) are only suitable for non-alloyed titanium, while higher temperatures are a requirement for alloyed titanium.

It's not just the temperature of the titanium itself that is essential during forging. The dies' temperature must also be controlled since excessive heat loss or variations in heat will lead to defective parts.

The importance of temperature in the titanium forging process is primarily related to the metal's structural elements at various heat levels. By forging with the correct heat levels of starting material and dies, the forger can create a more robust and reliable end product'one that is structurally suitable for the job at hand.

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