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<p>Tin bronze valve bodies are widely used in fluid control systems requiring high corrosion resistance. However, conventional casting introduces defects such as porosity, segregation, and “sweating tin,” while forging is limited by the alloy’s thermal brittleness and difficulty in forming complex geometries. These issues hinder the integration of structural complexity with high mechanical performance. To address this, a novel integrated casting-forging process is proposed, consisting of three stages: casting, thermal holding at forging temperature, and hot forging. Using C83600 tin bronze, hot compression tests were conducted to construct a processing map and determine the optimal hot working parameters. A coupled simulation framework based on THERCAST and FORGE was developed to model solidification, homogenization, and forging, validating the feasibility of both bidirectional and triaxial extrusion schemes. Experimental trials confirmed that forging the billet while hot enabled seamless process transition, enhanced stability, and reduced cycle time. The resulting valve bodies exhibited significantly improved density of 9.25&#xa0;g/cm<sup>3</sup> and mechanical properties, hardness of 169 HB. This integrated approach demonstrates clear technical feasibility and practical potential for high-performance tin bronze component manufacturing.</p>

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Design and optimization of an integrated casting-forging process for tin bronze valve bodies based on hot deformation behavior

  • 期刊论文

  • 发表日期：

    2025年8月4日

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  • Chunge Wang,
  • Yangbiao Zeng,
  • Xiang Yan,
  • Wen Liu,
  • Chaoyang Wang,
  • Binfeng Wang,
  • Meiling Zhou,
  • Zhu Xiao

摘要

Tin bronze valve bodies are widely used in fluid control systems requiring high corrosion resistance. However, conventional casting introduces defects such as porosity, segregation, and “sweating tin,” while forging is limited by the alloy’s thermal brittleness and difficulty in forming complex geometries. These issues hinder the integration of structural complexity with high mechanical performance. To address this, a novel integrated casting-forging process is proposed, consisting of three stages: casting, thermal holding at forging temperature, and hot forging. Using C83600 tin bronze, hot compression tests were conducted to construct a processing map and determine the optimal hot working parameters. A coupled simulation framework based on THERCAST and FORGE was developed to model solidification, homogenization, and forging, validating the feasibility of both bidirectional and triaxial extrusion schemes. Experimental trials confirmed that forging the billet while hot enabled seamless process transition, enhanced stability, and reduced cycle time. The resulting valve bodies exhibited significantly improved density of 9.25 g/cm3 and mechanical properties, hardness of 169 HB. This integrated approach demonstrates clear technical feasibility and practical potential for high-performance tin bronze component manufacturing.