A complete guide to magnesium alloy forging: master the method, advantages and industrial applications at once

1. Market trends and opportunities in magnesium alloy forging

 

The world's ultimate pursuit of lightweight

In the face of trends such as energy transition, net-zero carbon emissions, and the popularity of electric vehicles, how to reduce weight without sacrificing strength has become a core proposition for design engineers. Magnesium alloys, with their extremely low density (1.74 g/cm³) and good processability, have become the preferred lightweight metal materials in addition to aluminum alloys.

 

 Overview of the application of the four main industries:

• Aerospace industry: For example, Boeing and Airbus began to introduce magnesium alloys into cockpit frames, wing internal structural parts, etc., achieving the goal of saving tens of thousands of dollars in fuel costs per kilogram.

• Automotive manufacturing: Magnesium forgings are increasingly used in body structural parts such as A/B column reinforcement plates and steering wheel skeletons, reducing weight by 20%-40%.

• 3C electronic products: The internal components of laptops, tablets and smartphones are gradually replaced with aluminum alloys to improve anti-interference and durability.

• Medical Industry: Biocompatibility and absorbability make it the preferred choice for next-generation degradable implants (such as bone screws and splints).

 

Extended trend: China, the United States, Japan, and Germany have all invested in the development of semi-solid magnesium forging automation, and are expected to be introduced into mass production lines in the next five years.

 

2. Overview of magnesium alloy material properties

 

Comparison of material physics and mechanical properties of magnesium alloys

 

 Introduction to commonly used magnesium alloys and material selection suggestions

• AZ91D: High castability, suitable for laptop cases and camera internal structures after corrosion-resistant treatment.

• AM60: Excellent toughness and impact resistance, widely used in automotive crash protection parts.

• ZK60: Good forging performance, suitable for structural load-bearing elements and aerospace parts.

• WE43: Contains rare earth elements, has high strength and high temperature stability, and is commonly used in F1 racing cars and aerospace parts.

• MRI 230D：新型高溫鎂合金，適用於需承高熱環境的汽車零組件。

 

3. Analysis of magnesium alloy forging method

 

Hot Forging

• Common temperature range: 350°C~480°C.

•  It has good machinability and can be made into complex geometric pieces.

• The disadvantages are severe oxidation and high mold loss, and the atmosphere and lubrication system must be controlled.

 

Warm forging and cold forging

• Cold forging is uncommon due to the plastic limitations of magnesium alloys.

• Warm forging is a compromise between hot and cold forging, which can achieve medium high precision and good mechanical properties.

• Especially suitable for AM60 or ZK60 materials.

 

Semi-solid forging（Thixo-forging）

• It uses a liquid-solid mixture for forming to reduce flow resistance and forging pressure.

• It can be forged with integrated runners and structural parts at one time.

• The challenge is equipment cost and mold cooling control, but the defect rate can be greatly reduced.

 

4. Design considerations before forging

 

Key parameters in the design phase:

• Mold Design Life: Heat-resistant, high-toughness tool steels such as H13 or ESR H11 are required.

• Compression ratio and strain rate: It is recommended to maintain it in the range of 4~6 times to prevent cracks and stress concentration.

• FEA analysis points:

• Temperature Field Distribution Simulation (Heat Flow Analysis)

• Forging Load Prediction (Pressure, Speed Influence)

• Cavity filling and defect prediction (wrinkle, melt)

 

 5. Detailed explanation of the process steps

1. Billet preparation and homogenization treatment

   • It is commonly used as cast rod or calendered sheet, which needs to be homogenized at 400°C for 8~12 hours.
     
     

2.  The preheating curve is maintained with isothermal hold

   • The billet and the mold need to heat up synchronously, and the mold temperature is recommended to be controlled between 250~300°C to avoid overcooling.
     
     

3. Forging and molding stages

   • Closed-die or semi-closed die forging is often used, and the pressure speed needs to be increased step by step.

   • Some high-end production lines combine induction heating and servo forging technology.
     
     

4. Deburring and heat treatment

   • After the forging is completed, cooling, trimming, and T6 aging treatment (solution + manual aging) are carried out to improve fatigue resistance.

 

6. Common defects and solutions

 

 

9. Top 5 Indicators for Choosing the Right Forging Supplier

1. Mold and forging equipment capabilities: Whether it has 600~1600 tons of hydraulic pressure and induction heating support.Annual production capacity and delivery time: Those with a single daily production capacity of more than 1,000 pieces can undertake mass production demand.

2. Quality assurance and documentation capabilities: Whether documents such as PPAP, FAIR, IMDS, etc. can be provided.

3. Technical support capabilities: Whether there is engineering collaboration, can assist in early feasibility analysis and mold flow simulation.

4. Material traceability and risk control capabilities: It can provide complete traceability records of furnace number, raw material source, and heat treatment.

 

You are welcome to contact Pinda directly to learn more

 

 

 

10. Magnesium Alloy Forging FAQ and Design Suggestions

Q1: How much does it cost to open a mold for a magnesium alloy forging?
A: Depending on the complexity and size of the mold, it is generally NT$50,000~NT$150,000.

Q2: Can it replace aluminum forgings or castings?
A: If the application requires extremely high lightweight and does not require high corrosion resistance, it is a better option

Q3: What are the considerations for design conversion?

A: Magnesium alloys are easy to oxidize and are not suitable for welding, so it is recommended to replace welded assemblies with integral structural forging.

11. Conclusion: From design to mass production, magnesium alloy forging will be a key process in the future

 

Under the pressure of carbon neutrality and the demand for high performance, the demand for magnesium alloy forging will continue to rise.

Mastering the correct forging methods, material selection, and supply chain evaluation not only enhances product value but also holds the key to seizing the commanding heights of future manufacturing.

If you are evaluating a magnesium alloy forging project, it is recommended to work with a supplier that has the trinity of simulation analysis, mold making, and quality control verification to avoid development risks and shorten the timeline.

 You are welcome to contact Pinda directly to learn more