Forging improves magnesium die casting

 The automotive manufacturing has started a shift from iron and steel to aluminium engine and suspension components as stringent fuel consumption regulations loom. With a rapidly evolving eco-consciousness of car consumers worldwide, there is a greater focus towards more fuel-efficient products. But magnesium is an even lighter metal than aluminium and is already in use in some high-end sports cars and some high-mileage concepts.
 With magnesium as the new aluminium due to its excellent light weight, hot chamber magnesium die casting is gaining popularity in the manufacturing world. The process produces magnesium parts with precise dimensions in a variety of configurations, but it can be demanding on die casting machines, particularly on the gooseneck that delivers the molten magnesium to the die. By using forged, rather than the more commonly cast goosenecks, better machine performance and part quality will be yielded.
 Magnesium is becoming the lightweight manufacturing material of choice in high tech, space, auto and other industries because of its excellent strength-to-weight ratio, good dimensional stability, and recyclability. It isn't as brittle as aluminium.
 The hot chamber magnesium die casting process uses a gooseneck and piston to inject molten magnesium into a die. The gooseneck is submerged into molten magnesium, and through the side fill holes, the gooseneck cavity is filled with molten magnesium. The piston then forces the molten metal down from the top, delivering the metal through the gooseneck's vertical delivery hole, nozzle and into the die without exposure to the environment. After the metal turns solid inside the die cavity, the die opens, the part is ejected and at the same time the piston retracts to its initial position above the fill holes. Then again, the die is closed, and the gooseneck is filled with molten metal and ready for the next injection.
Forging is an attractive alternative for the cast goosenecks. In the forging process, a solid billet can be shaped on open die presses, which consolidate the ingot centre and eliminate porosity. It delivers a superior finished product that is more reliable and lasts longer.

 Forging tips
Use presses ranging from 750 to 5500 tonnes, which can produce shafts with any combination of round cylindrical, square, flat or polygonal dimensions.
Use a high-quality, cost-efficient forging solution that offers a proactive partnership program in which they work with machine shops and metal part buyers to optimise part quality, while minimising waste and reducing costs. The program must be led by an experienced metallurgist, designed to discover ways for producing high quality parts less expensively using the forging process. This identifies and eliminates unnecessary processing while improving part strength, often by combining multiple components into one higher-strength part.
Some companies proposed a creative two-in-one solution that yielded cost and material savings. You can save costs by making one forging that would yield two goosenecks. Start with a billet on one of your open die hydraulic presses; make a square centre section, then use a fuller tool to mark the step downs on either end. We then shape the step downs into round journals. Forging the goosenecks this way makes machining and processing much easier.
In addition, look for a company who can assist you with material selection, specialty alloys, and custom melts. Someone who can help find an alternative to steel specified for casting. Bear in mind that the “alternative” must stand up under the chemical abrasivenessAir VaporMax Shoes