Dalian forging processing: improving material density and creating high-strength industrial components

Dalian forging processing: improving material density and creating high-strength industrial components

Dalian forging processing uses external forces to cause plastic deformation of metal billets, reshaping the internal structure of materials and becoming the core process for improving component strength. The core logic is to break and reorganize metal grains through forging, eliminate defects such as porosity and looseness in the cast state, and achieve a significant increase in material density, laying the foundation for high-strength industrial components.

During the forging process, metal flow occurs synchronously with grain refinement. When the press applies an external force of 500-3000 tons, the original cast grains inside the steel billet are elongated and broken, and then recrystallized at high temperature (hot forging) or room temperature (cold forging), forming uniform and fine equiaxed grains. This structural adjustment increases the density of the material from 92% -95% in the cast state to over 99.5%, just like compacting loose sand piles into hard stones. Taking the automobile half axle as an example, the forged 40Cr steel has a 7% increase in density, an increase in tensile strength from 800MPa to 1000MPa, a 40% increase in fracture toughness, and can withstand greater impact loads.

The improvement in density directly translates into the enhancement of multidimensional mechanical properties. In the valve disc processing of high-pressure valves, forging technology eliminates internal microcracks, making it leak free under a working pressure of 30MPa, and its service life is three times that of castings; After the wind turbine flange is ring forged, the material fibers are continuously distributed along the circumferential direction, and the fatigue strength is increased by 50%, which can withstand decades of alternating loads. More importantly, the anisotropy of forged parts is significantly reduced - the difference in mechanical properties of the same part in different directions is controlled within 5%, avoiding local premature failure caused by uneven microstructure of castings.

This process characteristic makes it a preferred choice for high-strength components. The turbine disk of an aircraft engine is precision forged and maintains 90% room temperature strength at a high temperature of 1000 ℃, relying on nearly 100% material density; The hydraulic cylinder piston rod of construction machinery is strengthened by cold forging, with a surface hardness of HRC55 and an increased internal density, resulting in an increase in pressure resistance from 25MPa to 35MPa. According to statistics from a heavy truck factory, the use of forged connecting rods has extended the engine overhaul cycle from 300000 kilometers to 500000 kilometers, directly reducing maintenance costs.

From the reorganization of microscopic grains to the leap in macroscopic performance, Dalian forging processing focuses on improving material density, endowing industrial components with strength and reliability beyond conventional standards, and becoming a key process for ensuring safety and lifespan in high-end equipment manufacturing.