Research Projects

Compound Liquid Forging for Lightweight Components


Liquid Forging has enabled strong direct bonding between aluminium and magnesium alloys in future components. In this compound forging, the first aluminium section from wrought alloy 6061 is Liquid Forged and heat treated to reach stable aged condition 6061-T6. Subsequently, this section is subjected to a second Liquid Forging process where molten cast magnesium alloy AZ91 is added to produce direct bonding between the two alloys.

 

This method offered up to 20% weight reduction from conventional monolithic aluminium Liquid Forged product, while eliminating need of brazing or complex surface treatment. In the variations of compound Liquid Forging, wrought aluminium alloys have been successfully direct-bonded to other materials such as copper, alumina, and thermal pyrolytic graphite (TPG).

Contact PersonChua Beng Wah(bwchua@SIMTech.a-star.edu.sg)
Solution

This method offered up to 20% weight reduction from conventional monolithic aluminium Liquid Forged product, while eliminating need of brazing or complex surface treatment. In the variations of compound Liquid Forging, wrought aluminium alloys have been successfully direct-bonded to other materials such as copper, alumina, and thermal pyrolytic graphite (TPG).

Applications

Problems Addressed

The main research in compound Liquid Forging is on the improvement of bond strength between the two materials through microscopic mechanical interlocking and atomic diffusion, while working with material incompatibility in terms of thermal expansion difference and possible formation of undesirable interfacial phases.