Analyzing Forged Quality of Thin-Walled A-286 Superalloy Tube under Multi-Stage Cold Forging Processes

Cold forging is suitable for manufacturing thin-walled tubes; however, a poorly planned forging process results in serious quality problems. This paper aims to determine an appropriate cold forging process for thin-walled A286 superalloy tube with ideal forming quality. We analyzed the effects of th...

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Bibliographic Details
Published in:Materials 2023-06, Vol.16 (13), p.4598
Main Authors: Tao, Liang, Feng, Zhiguo, Jiang, Yulian, Tong, Jinfang
Format: Article
Language:English
Subjects:
Cold
Cold forging
Crack initiation
Defects
Finite element method
Hardness
Mechanical properties
Microhardness
Optical microscopes
Plastic deformation
Simulation
Simulation methods
Strain distribution
Stress concentration
Superalloys
Titanium alloys
Tubes
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Summary:Cold forging is suitable for manufacturing thin-walled tubes; however, a poorly planned forging process results in serious quality problems. This paper aims to determine an appropriate cold forging process for thin-walled A286 superalloy tube with ideal forming quality. We analyzed the effects of the two forging processes with reverse forging sequences on forming defects and hardness distribution in the thin-walled tubes via finite element simulation. The methods of optical microscope, micro-hardness, scanning electron microscope, and electron-backscattered diffraction were used to validate the tube forming quality. The simulation results revealed that the Type-I process was an appropriate forging process for meeting the quality requirements. For the Type-I process, an underfilling defect was observed at the bottom of the rod section of the tube. The stress concentration in the head section was lower than that in the Type-II process, potentially reducing the probability of crack initiation. Compared to the rod section, the head section may exhibit higher hardness magnitudes due to the greater strain distribution. The experimental results confirmed the feasibility of the Type-I process. The increased hardness in the head section may be primarily attributed to the more intense plastic deformation applied to the material in this section by the Type-I process.
ISSN:1996-1944
1996-1944
DOI:10.3390/ma16134598