Forging Defects

S. Arvind Joshua Jaydev (20082203)

Defects in Forging may Arise from:

Inherent Defects while forging Faulty cuts in Forging Operations Improper Heating and Cooling

Types of Defects in Forging

1. Cracks 2. Laps/Folds 3. Pitting 4. Coarse Grain Wrinkle 5. Flow-through 6. Distributed Metal Defects 7. Dents 8. Underfilling 9. Void at Base of Rib 10.Push-through of Web under Rib

1. Cracks
Excessive working of a surface at too low a temperature leads to cracks Cracks may nucleate due to sulphur inclusions, etc. External cracks are most dangerous Cracks may appear at flash (if flash is too thin) Internal cracks may develop during Upsetting

Inclusions leading to cracking

Cavity in the centre of a cleavage facet. The small inclusion appears to have initiated cleavage fracture.

Upsetting Forging

Flash

Combating cracks in Forging

Forging at increased temperature Stress relieving before cutting off flash Hot-cutting of Flash Use concave die while upsetting.

2. Laps/Folds
Also called Fold-shut Occurs when two surfaces of a metal folds against each other without welding completely Metal may flow past a die cavity that has already been filled. May be due to Too small die radius, excessive chilling of high friction

Example of Folding during Forging

3. Pitting

Pitting
Pitting occurs because of incomplete cleaning of Die Die and workpiece should be free from scale while forging

4. Coarse grain Wrinkle

Wrinkling occurs during forging because the Billets contains coarse grains. These wrinkles fold into laps during forging.

5. Flow-through

Also
Flow through may occur in cases where metal flows past the die recesses after filling. Die impressions are hence not completely filled. Maybe avoided by increasing temp. of stock Ensure lubricants are not trapped

6. Distributed Metal Defects

Loose oxides minimized die-slug contact Avoid too much lubricant

7. Dents

Dents are caused by

Improper positioning of stock on die Throwing around the forging while it is still hot.

8. Underfilling

Underfilling
Metal does not fill the recesses of the die completely Because of loose scale and lubricant residue that accumulates in deep recesses of the die

9. Rib and Web defects

A "peeling" lap forms in an aluminum rib-web forging as the corner of the die forces surface material ahead of the contact region. With a redesign of the upper die or preform, this type of defect can be prevented

References
Mechanical Metallurgy, G. E. Dieter http://www.forgemag.com Google Images