Deformation and fracture characteristics of complex Al-Si alloy during high speed forging under different processing conditions

The feasibility of bulk processing of complex Al-Si alloy (Al-18Si-2.5Cu-0.6Fe) has been demonstrated in the present work. Open and closed die forging experiments have been performed using solid cylindrical billets under different conditions of working temperatures, aspect ratios and interfacial friction between top-bottom dies and test samples. The results so obtained, have been critically analysed and discussed to explain the deformation and fracture behaviour of the above Al-Si alloy. Results reveal that due to the presence of hard silicon and intermetallic particles in the alloy, the open die forging of the test sample generates severe surface cracks during deformation under cold and hot processing conditions. However, the high speed closed die forging of above complex Al-Si alloy at elevated temperatures show encouraging results. The forged component so produced is free from surface cracks and possess improved engineering properties.