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Control of the dimensions of heated forgings is a mandatory operation during processing on a forging press. At most enterprises, measurements are carried out manually using mechanical tools—calipers, crown calipers, metal rulers. This method of control has a number of significant drawbacks that reduce the efficiency of forging and increase the risk of producing defective products. The paper considers the main drawbacks and assesses the errors of the manual method, and proposes a solution for automating the control of the dimensions of hot cylindrical forgings using the Gefest photogrammetric system.

Ecological manageability in manufacturing these days is a dire and exceptional issue and the principle concerns are identified with increasingly proficient utilization of energy and materials. Recycling can save a large amount greenhouse gas emissions, particularly in the case of aluminum. The parameter on the innovative technique on the direct recycling was investigated by employing design of experiments, via hot press forging process (DR-HPF). Thus, reutilizing of aluminum chips AA6061 with full factorial 32 design of experiment comprising a variety of working temperature and holding time were employed. Central composite design (CCD) was applied to outline the experiments towards evaluating the influences of the hot press forging parameters to the three responses; ultimate tensile strength (UTS), elongation to failure (ETF), and global warming potential (GWP). In conjunction with this, the environmental impacts associated with DR-HPF process are evaluated alongside the resultant conventional recycling (CR) by using re-melting route as indication. Experimental measurements, literature analysis and industrial data were merged to acquire the analysis of aluminum recycling life cycle. Clear conclusions were successfully drawn through the attained results on the outlook proposed by solid state direct recycling for the purpose of reducing the environmental effects by taking material and energy conservation as one of the most essential impacting factor. The global warming potential of a DR-HPF route gives a significant environmental impact where it is reduced up to 69.2% in comparison to the conventional (melting) routes.

The primary objective of this research is to investigate the process of direct recycling of AA7075 aluminium alloy, which is extensively utilised in the aerospace and flight sectors due to its exceptional strength and lightweight characteristics. Alumina (Al 2 O 3 ) is used as a reinforcing agent and the effect of hot press forging (HPF) parameters on the mechanical characteristics and surface integrity of the metal matrix composite (MMC) constructed of AA7075 alloy with 1% Al 2 O 3  has been studied. Furthermore, the utilisation of an integrated life cycle assessment (LCA) approach is implemented to assess the environmental impacts and economic expenses associated with the recycling of aluminium via high-pressure forming for both the metal matrix composite and AA7075 alloy. Response surface methodology (RSM) is applied to ascertain the optimal parameters for high-performance filtration. The findings suggest that employing a forging temperature of 532.34 °C and a holding time of 60 min produces favourable results. When comparing the characteristics of the MMC and recycled aluminium, it can be observed that they both demonstrate similar essential process attributes. The utilisation of HPF in conjunction with the Multi-Material Composite has the potential to yield a reduction of up to 24.97% in Global Warming Potential (GWP). This research demonstrates the efficacy of HPF as a viable approach for environmentally conscious and economically efficient recycling of AA7075 aluminium scrap, thereby improving product performance and promoting sustainability.

The current practice in aluminum recycling plants is to change the waste into molten metal through the conventional recycling (CR) manufacturing process. However, the CR technique is so energy-intensive that it also poses an indirect threat to the environment. This paper presents a study on meltless direct recycling hot press forging (DR-HPF) as an alternative sustainable approach that has fewer steps with low energy consumption, as well as preventing the generation of new waste. A laboratory experiment was conducted to study the mechanical properties and surface integrity of AA7075 aluminum alloy by employing a hot press forging (HPF) process under different temperatures (380, 430, and 480 °C) and holding times (0, 60, and 120 min). It was found that as the parameter increased, there was a positive increase in ultimate tensile strength (UTS), elongation to failure (ETF), density, and microhardness. The recycled chips exhibit the best mechanical properties at the highest parameters (480 °C and 120 min), whereas the UTS = 245.62 MPa and ETF = 6.91%, while surface integrity shows that the calculated microhardness and density are 69.02 HV and 2.795 g/cm3, respectively. The UTS result shows that the highest parameters of 480 °C and 120 min are comparable with the Aerospace Specification Metals (ASM) Aluminum AA7075-O standard. This study is a guide for machinists and the manufacturing industry to increase industry sustainability, to preserve the earth for future generations.

Purpose The purpose of this study is to report results of the qualitative assessment of AZ31 aircraft brackets with a triangular rib produced by a new forging method with respect to their structure and mechanical properties. Design/methodology/approach The paper reports the results of qualitative tests for AZ31 magnesium alloy aircraft brackets with a triangular rib produced by a new forging method. These ribbed parts were formed on a forging press equipped with three moving tools. The produced aircraft brackets were subjected to qualitative tests. Their cross-sectional microstructure was examined using the light-field technique. The mechanical properties of ribbed parts were determined in a static tensile test and by hardness measurements on the surface of the part. The following variables were determined: tensile strength Rm, yield strength R0.2, elongation A5 and hardness. Findings The results of qualitative tests provide significant information about produced aircraft brackets with a triangular rib, i.e. microstructure in three key regions of brackets and their mechanical properties. Practical implications The method will enable producing magnesium alloy aircraft brackets with a triangular rib. The application of the method for aircraft brackets developed by the authors of this paper will result in higher product quality and reduced production costs. The paper demonstrates the practical application of this technique by presenting a finished aircraft bracket and the results of complete qualitative tests. Originality/value The originality of this paper lies in the presentation of a new, innovative method for manufacturing aircraft brackets with a triangular rib. This method is unique on a global scale, and its assumptions have been granted patent protection.

In this study, the response surface methodology (RSM) and desirability function (DF) were utilized to optimize the recycling conditions of aluminum (AA6061) chips, in the presence of particulate alumina (Al2O3), to obtain a metal matrix composite of recycled aluminum (MMC-AlR) using hot press forging processes. The effects of temperature (430–530 °C) and holding time (60–120 min) were investigated. The introduction of 2.0 wt. % of Al2O3 to the aluminum matrix was based on preliminary research and some pilot tests. This study employed the 2k factorial design of experiments that should satisfy the operating temperatures (T) of 430 °C and 530 °C with holding times (t) of 60 min and 120 min. The central composite design (CCD) was utilized for RSM with the axial and center point to evaluate the responses to the ultimate tensile strength (UTS), elongation to failure (ETF), and microhardness (MH). Based on RSM, with the desirability of 97.6%, the significant parameters T = 530 °C and t = 120 min were suggested to yield an optimized composite performance with UTS = 317.99 MPa, ETF = 20.45%, and MH = 86.656 HV. Three confirmation runs were performed based on the suggested optimum parameters, and the error revealed was less than 25%. The mathematical models suggested by RSM could adequately describe the MMC-AlR responses of the factors being investigated.

Precision forgings represent a critical area of industrial research. However, existing model-based control methods often rely on empirical values to simplify the force conditions of the guide pillars in die forging presses, resulting in insufficient model accuracy throughout the entire forging process and adversely affecting the dimensional quality of precision forgings. To address this issue, this paper develops a novel mechanical model for the guide pillars of die forging presses, which is validated against finite element simulations performed using COMSOL software. The simulation results indicated that the mechanical model exhibited minor errors compared to the finite element analysis result, thereby it is effective to use this physical model to acquire precise control, supporting more precise model-based control of the complete forging process.

Metallic material processing plays a significant role in terms of global environmental impact which contributes to the climate change phenomena that is a serious international environmental concern and the subject of much research and debate. Thus, energy-and resource-efficient strategies in the metal shaping technology domain need to be identified urgently. A frequent theme in the debates that surround waste and resources management is the extent to which the recycling of metallic materials offers genuine benefits to the environment. Solid state recycling techniques allow the manufacture of high density aluminum alloy parts directly from production scrap. In this paper the environmental impacts associated with ‘meltless’ scrap processing routes through hot press forging process with varying parameter has been studied. A comparative analysis has been performed, with different operating temperature and holding time of direct recycling hot press forging process AA6061 aluminum chip. The importance of an environmental performance analysis that included both parameter setting was discussed and highlighted throughout the paper. Finally, the application of the proposed parameter setup has resulted in the setting up of an eco-process. Indeed, LCA study on recycling (solid-state) are recommended as well it gives a noteworthy benefit to the environment and to fill the knowledge gap.

Data on the production of blanks for gas-turbine engines and power units in the 200 MN die-forging press at the Electrostal Metallurgical Plant are presented. The range of geometries and grades of blanks produced in the 200 MN press is described.

Purpose – The purpose of this research is working out of a new forming technology of flat parts with ribs from magnesium alloys with the application of a three-slide forging press (TSFP) for the aircraft industry. Design/methodology/approach – New possibilities of forming aviation parts with ribs gives the application of a prototype TSFP. This press consists of three moveable tools and has wider technological possibilities than typical forging machines. It was assumed that this machine (press) application would allow for obtaining ribbed flat forgings from magnesium alloys of good functional and resistance qualities. A characteristic feature of such forgings forming is the working movement of two side tools, which upset the billet in the form of a plate; the result of their action is forming of one or more ribs in the plane central part. It is possible to use the upper punch to form appropriate rib outline. Theoretical research works based on simulations by means of finite element method were conducted for three cases of the process: semi-free forging of parts with one rib, semi-free forming of forgings with two ribs and forging in closed impression of parts with one rib of triangular outline. The first experimental tests were made on a TSFP for the variant of semi-free forging of parts with one rib. Findings – Research results show that there exists the possibility of realization of forming process of parts with ribs according to the conception assumed by the authors. Positive results of theoretical analyses justify the purposefulness of conducting experimental verification for the proposed theoretical solutions of the forging processes of parts with one rib of triangular outline and with two ribs. Practical implications – Production of flat parts with ribs from magnesium alloys basing on the worked out by the authors’ technology will allow for improving functional and mechanical properties of parts and for lowering their manufacturing costs. At present, such aviation parts are imported to Poland in the form of casts, which are expensive and not always fulfill the requirements. Additionally, large amount of machining at manufacturing of this type of parts generate larger price at their production. Originality/value – Forging technology of parts with ribs in a TSFP is unique on a world scale. The advantages of this technology are the process material savings and better resistance properties of the formed forgings with ribs than parts obtained in a traditional way.