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<p>In this paper, characterization methods such as optical microscopy (OM) and scanning electron microscopy (SEM) were used, in combination with the Anycasting simulation software, to investigate the mechanisms by which mold design and process parameters affect the microstructure and properties of Al-Cu alloy flat plates prepared by integrated squeeze casting and forging. Through the mold design of “pulling + forging,” material flow was achieved, thereby realizing the goal of integral forging. The orthogonal experiment indicates that when the pouring temperature is 700 °C, the injection speed is 0.2&#xa0;m/s, the casting–forging interval is 9&#xa0;s, and the forging pressure is 16&#xa0;MPa, the resulting flat plate has fewer shrinkage porosity, shrinkage cavities, segregation, and crack defects, and the highest tensile strength. The process parameter that has the greatest impact on the tensile strength of the alloy is the casting–forging interval. When the casting–forging interval is 9 seconds, the convection caused by forging will wash away the dendrite arms. The detached dendrite arms will form new grains, thereby achieving the goal of grain refinement. At the same time, the convection and stirring effects generated during the forging process result in smaller concentration differences of the alloying elements throughout the melt. This leads to a solidified structure with minimal compositional segregation and a “streamlined” grain morphology. Such a microstructure enhances the mechanical properties of the alloy. Under the aforementioned parameters, the average tensile strength of the alloy reaches 445&#xa0;MPa.</p>

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In Situ Forging during Casting Achieves the Preparation of Short-Process High-Performance Aluminum Alloy Components with Fine-Grained and Streamlined Structures

  • 期刊论文

  • 发表日期：

    2026年1月14日

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  • Chenxi Ma,
  • Jiongshen Chen,
  • Peng Shen,
  • Guojin Song,
  • Hui Huang

摘要

In this paper, characterization methods such as optical microscopy (OM) and scanning electron microscopy (SEM) were used, in combination with the Anycasting simulation software, to investigate the mechanisms by which mold design and process parameters affect the microstructure and properties of Al-Cu alloy flat plates prepared by integrated squeeze casting and forging. Through the mold design of “pulling + forging,” material flow was achieved, thereby realizing the goal of integral forging. The orthogonal experiment indicates that when the pouring temperature is 700 °C, the injection speed is 0.2 m/s, the casting–forging interval is 9 s, and the forging pressure is 16 MPa, the resulting flat plate has fewer shrinkage porosity, shrinkage cavities, segregation, and crack defects, and the highest tensile strength. The process parameter that has the greatest impact on the tensile strength of the alloy is the casting–forging interval. When the casting–forging interval is 9 seconds, the convection caused by forging will wash away the dendrite arms. The detached dendrite arms will form new grains, thereby achieving the goal of grain refinement. At the same time, the convection and stirring effects generated during the forging process result in smaller concentration differences of the alloying elements throughout the melt. This leads to a solidified structure with minimal compositional segregation and a “streamlined” grain morphology. Such a microstructure enhances the mechanical properties of the alloy. Under the aforementioned parameters, the average tensile strength of the alloy reaches 445 MPa.