Custom Aluminum Alloy Forgings Company
Manufacturing Process of Aluminum Forging Parts
Aluminum Closed Die Forging
Aluminum closed-die forging heats the aluminum alloy to a set temperature. Then, a special closed die presses the metal into its final shape. This method creates aluminum forgings that are very precise. They have great strength and a smooth surface finish.
Mass Production: This process is perfect for making parts in large numbers.
High Accuracy: The aluminum forgings come out with very exact sizes and dimensions.
Excellent Strength: The final forgings have superb mechanical properties.
Aluminum Ring Forging
This forging method makes aluminum parts shaped like rings. We heat the aluminum blank first. We put the hot aluminum into a mold or forging equipment. We then use pressure. This forces the metal to flow and form the final aluminum ring forging.
Used to make parts with complex shapes easily.
Best for medium and large production runs.
The final forgings have high strength and toughness.
Aluminum Cold Forging
Aluminum cold forging shapes a aluminum blank at room temperature. We use pressure to change the aluminum's shape without heating it. This method creates parts with high precision and better mechanical strength.
Precise Finish: Parts have very close size limits (tight tolerances) and a good surface finish.
Stronger Steel: It boosts the aluminum's strength and hardness, making the part last longer.
Saves Material: It cuts down on wasted material and the need for extra machining.
High Performance: The aluminum forgings come out with higher strength and toughness.
Heat Treatment
Heat treatment changes the inside of aluminum forging parts. It uses steps like heating, holding heat, and cooling. This process makes the metal better. It improves how aluminum parts work, helps them last longer, and makes them easier to shape.
It makes aluminum forgings harder and stronger.
It improves the toughness of the aluminum.
It boosts wear resistance and corrosion resistance (fighting rust).
Machining
Machining is a final step for aluminum forgings. It uses fine tools to improve the parts. This work boosts the accuracy, makes the surface much cleaner, and improves what the forging can do.
It makes the final look better.
It improves the part's structure and function.
It lets us make thin walls and complex shapes.
Surface Treatment
Surface treatment is the final step for aluminum forgings. We change the surface using chemical, electrical, or physical methods. This work protects the part from the environment, improves its look, and makes it ready for paint or assembly.
Improved Durability: Treatment adds a protective layer. This layer fights corrosion, wear, and scratches.
Enhanced Appearance: It improves the final look, offering options like bright colors or a clean, matte finish.
Better Function: Treatment helps bond the part to other materials and provides electrical insulation when needed.
Different Materials of Aluminum Forgings
Non-Heat-Treatable Aluminum Alloys Forging
These aluminum alloys get strength from cold shaping. They do not use heat to become strong. Their strength comes from working the metal when it is cold. This makes them great for parts needing good shape change and rust defense. They only need moderate strength.
Forged Non-Heat-Treatable Aluminum Parts from Simis:
Ship and marine parts;
Chemical gear;
Electrical power bars;
Cold storage tanks;
Car body panels;
Building structures;
Food gear.
Simis can forged non-heat-treatable aluminum alloys types:
Pure Aluminum Forgings (Low-Alloy): Electrical wire, heat exchangers, chemical tools, and decoration.
Al-Manganese (Al-Mn) Forgings: Cooking tools, heat exchangers, storage tanks, and building parts.
Al-Magnesium (Al-Mg) Forgings: Marine hardware, boat parts, pressure tanks, and transport gear.
Al-Mg-Silicon (Al-Mg-Si) Forgings: Building parts, car panels, and general use (some types are non-heat-treatable).
Aluminum-Copper Alloys Forging
Forged Aluminum-Copper alloys are produced by heating and mechanically pressing the aluminum and copper mixture. They are subsequently processed using heat treatment to achieve their maximum strength. These alloys are among the highest strength aluminum materials available, providing an exceptional strength-to-weight ratio and good fatigue resistance. This makes them suitable for high-performance structural components.
Forged Al-Cu Components from Simis Aluminum Forging Factory:
Aircraft body frames and structure parts;
Car suspension parts and wheels;
High-performance sports gear;
Robotic arms;
Machinery parts.
Simis can forged Al-Cu alloys types:
Binary Al-Cu Alloys: General high-strength structural parts, car parts, and machinery components.
Al-Cu with Magnesium Added: Aircraft structure parts, truck frames, and high-stress components.
Al-Cu with Lithium Added: High-performance car parts.
Highest-Strength Al-Cu Forgings: High-performance racing parts.
Aluminum-Magnesium-Silicon Alloys Forging
Forged Al-Mg-Si alloys are made by heating the metal and pressing it into shape. We then use special heat treatment to reach the best strength. These alloys offer a great balance of medium-to-high strength, good rust defense, and excellent ability to be extruded. This makes them one of the most useful and widely used aluminum alloy families.
Forged Al-Mg-Si Components from Simis Aluminum Forging Factory:
Car chassis and body structures;
Bicycle frames and parts;
Building structures;
Heat exchanger parts;
Marine hardware;
Electrical conductors;
General machine parts.
Simis can forged Al-Mg-Si alloys types:
Balanced Mg₂Si Alloy Forgings: General structural parts, car parts, and building uses.
High-Silicon Alloy Forgings: High-strength structure parts, wear-resistant parts, and car suspension.
High-Magnesium Alloy Forgings: Marine structures, pressure tanks, and transport equipment parts.
Copper-Containing Alloy Forgings: High-strength structure parts, aerospace parts, and precision machines.
Aluminum-Zinc Alloys Forging
Forged aluminum-zinc alloys are shaped by heating and pressing billets. They get strong naturally, without a special heat treatment step. This makes them high in strength and cost-effective for structural uses. They are best for jobs needing high strength but simple processing.
Forged Al-Zn Components from Simis Aluminum Forging Factory:
Car engine mounts and brackets;
Structural hardware;
Machine parts and fittings;
Electrical hardware;
General engineering components;
Architectural fittings.
Simis can forged Al-Zn alloys types:
High-Zinc Aluminum Alloy Forgings: Car structure parts, high-strength machine parts, and structural fittings.
Zinc-Magnesium Alloy Forgings: General structural parts, marine hardware, and transport equipment.
Zinc-Copper Alloy Forgings: High-strength structural parts, aerospace parts, and precision machines.
Low-Zinc Alloy Forgings: Marine parts, building structures, and general engineering.
Non-Heat-Treatable Aluminum Alloys Forging
These aluminum alloys get strength from cold shaping. They do not use heat to become strong. Their strength comes from working the metal when it is cold. This makes them great for parts needing good shape change and rust defense. They only need moderate strength.
Forged Non-Heat-Treatable Aluminum Parts from Simis:
Ship and marine parts;
Chemical gear;
Electrical power bars;
Cold storage tanks;
Car body panels;
Building structures;
Food gear.
Simis can forged non-heat-treatable aluminum alloys types:
Pure Aluminum Forgings (Low-Alloy): Electrical wire, heat exchangers, chemical tools, and decoration.
Al-Manganese (Al-Mn) Forgings: Cooking tools, heat exchangers, storage tanks, and building parts.
Al-Magnesium (Al-Mg) Forgings: Marine hardware, boat parts, pressure tanks, and transport gear.
Al-Mg-Silicon (Al-Mg-Si) Forgings: Building parts, car panels, and general use (some types are non-heat-treatable).
Aluminum-Copper Alloys Forging
Forged Aluminum-Copper alloys are produced by heating and mechanically pressing the aluminum and copper mixture. They are subsequently processed using heat treatment to achieve their maximum strength. These alloys are among the highest strength aluminum materials available, providing an exceptional strength-to-weight ratio and good fatigue resistance. This makes them suitable for high-performance structural components.
Forged Al-Cu Components from Simis Aluminum Forging Factory:
Aircraft body frames and structure parts;
Car suspension parts and wheels;
High-performance sports gear;
Robotic arms;
Machinery parts.
Simis can forged Al-Cu alloys types:
Binary Al-Cu Alloys: General high-strength structural parts, car parts, and machinery components.
Al-Cu with Magnesium Added: Aircraft structure parts, truck frames, and high-stress components.
Al-Cu with Lithium Added: High-performance car parts.
Highest-Strength Al-Cu Forgings: High-performance racing parts.
Aluminum-Magnesium-Silicon Alloys Forging
Forged Al-Mg-Si alloys are made by heating the metal and pressing it into shape. We then use special heat treatment to reach the best strength. These alloys offer a great balance of medium-to-high strength, good rust defense, and excellent ability to be extruded. This makes them one of the most useful and widely used aluminum alloy families.
Forged Al-Mg-Si Components from Simis Aluminum Forging Factory:
Car chassis and body structures;
Bicycle frames and parts;
Building structures;
Heat exchanger parts;
Marine hardware;
Electrical conductors;
General machine parts.
Simis can forged Al-Mg-Si alloys types:
Balanced Mg₂Si Alloy Forgings: General structural parts, car parts, and building uses.
High-Silicon Alloy Forgings: High-strength structure parts, wear-resistant parts, and car suspension.
High-Magnesium Alloy Forgings: Marine structures, pressure tanks, and transport equipment parts.
Copper-Containing Alloy Forgings: High-strength structure parts, aerospace parts, and precision machines.
Aluminum-Zinc Alloys Forging
Forged aluminum-zinc alloys are shaped by heating and pressing billets. They get strong naturally, without a special heat treatment step. This makes them high in strength and cost-effective for structural uses. They are best for jobs needing high strength but simple processing.
Forged Al-Zn Components from Simis Aluminum Forging Factory:
Car engine mounts and brackets;
Structural hardware;
Machine parts and fittings;
Electrical hardware;
General engineering components;
Architectural fittings.
Simis can forged Al-Zn alloys types:
High-Zinc Aluminum Alloy Forgings: Car structure parts, high-strength machine parts, and structural fittings.
Zinc-Magnesium Alloy Forgings: General structural parts, marine hardware, and transport equipment.
Zinc-Copper Alloy Forgings: High-strength structural parts, aerospace parts, and precision machines.
Low-Zinc Alloy Forgings: Marine parts, building structures, and general engineering.
Application of Aluminum Forgings
Custom Aluminum Forgings by Simis Forging Factory
Aluminum Forging Company's Custom Steps
Confirm customization requirements
Design Review and Samples
Simis engineers first check the 3D and plane drawings. This makes sure your design is ready for the forging process. If you have a sample part, we can make the new parts based on that sample.
Define Part Requirements
We confirm what the part needs to do. This includes things like its strength, hardness, wear, and rust resistance. We also set the exact size, tolerance, and finish quality needed for the forged part.
Confirm Forging Material
Our engineers help you pick the right aluminum material. This choice depends on where the part will be used and your technical needs. We give advice based on material cost, strength, and resistance to wear or rust.
Choose the Forging Process
We select the best forging process for your part. We base this choice on your price goal, the part’s shape, its required dimensional accuracy, and the material.
Make Dies and Samples
We build the forging dies (molds) using your approved drawings or samples. Then, we shape the aluminum material through the chosen process to produce the first batch of samples.
Full Sample Inspection
The finished samples go through a full check. This confirms they meet all design standards and your quality demands. We give you reports covering size and tolerance inspection, performance testing, chemical composition analysis, and non-destructive testing.
Production and quality control
7. Mass Production
After you check and approve the sample, we start the mass production plan. We get all the materials ready based on your order. We use the exact same forging equipment and process as we did for the sample. This makes sure every single part we make is the same.
8. Quality Control During Production
We run tight quality checks while making the parts. We pull parts for checks often during the process. We test their size, look, and strength. This ensures every batch of forged aluminum parts is consistent and meets your needs.
9. Final Product Quality Inspection
We use multiple inspectors for the final check. They do many tests on the finished product. These tests cover size accuracy, surface quality, and part strength. This step makes sure all forged aluminum parts meet your quality standards.
10. Packaging and Delivery
We securely package and ship all approved parts. We pick the right packaging to prevent damage during shipping. We also choose the best delivery method (air, sea, or land) to get your parts to you on time.
To order custom parts, please email us your design drawings and 3D models. Our team will review the detailed part parameters and the 3D model to provide you with an accurate quote.