Research Projects

Liquid Forging of Metal Alloys to Produce Pore Free Components

Liquid forging is a hybrid of conventional squeeze casting and forging techniques which combines the excellent mechanical properties of forging with the economies and the shape capabilities of casting. This innovative process for forming metal components is able to produce dimensionally accurate (net shape) parts and mechanically strong components coupled with the ability to reduce manufacturing cost by cutting down on material waste generation and using cheaper material. Successful development of this process by SIMTech has led to the net shape forming of components with intricate features, which are not possible to produce by conventional forging techniques due to the high load requirements.



Contact PersonChua Beng Wah(bwchua@SIMTech.a-star.edu.sg)
SolutionLiquid forging technique eliminates micro/macro porosity (shrinkage and gas) due to pressurised solidification. Isotropic properties are achieved due to its ability to produce parts with complex profile and thin section of about 250 micron beyond the capability of conventional casting and forging techniques.
BenefitsUS Patent No. 60/658,171, "Method and Apparatus for Forging”, filed on 30 March 2005.
Patents / Awards / Achievements / DifferentiationUS Patent No. 60/658,171, "Method and Apparatus for Forging”, filed on 30 March 2005.
Applications
Liquid forging process is competent to produce components for several sectors including automotive, aerospace, precision engineering, electronics, data storage, etc.

Problems Addressed

Shrinkage and gas porosity are commonly found defects in castings. These defects will affect the mechanical properties of the components. Thin sections are beyond the capability of conventional casting and forging techniques.