Metal injection molding and forging are both processing processes for metal products, but they are two completely different processing methods. Metal injection molding technology uses metal powder as raw material to produce complex shape and internal structure parts by mixing metal powder, forming and sintering steps, which has high design freedom; Forging uses massive metal materials by applying force to the massive metal materials, so that it is deformed at high temperature to achieve formation, forging in the forming process is limited by the plasticity of the material, it is difficult to achieve complex shape and internal structure.
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What Is Metal Forging?
Metal forging is a processing method that uses forging machinery to exert pressure on the metal blank to produce plastic deformation in order to obtain forgings with certain mechanical properties, shapes, and sizes.
Metal Forging Material List
Hot forging is an important metal processing method, that can improve the performance and shape of the material through plastic deformation, but not all metal materials can be used hot forging process, the following are commonly used hot forging materials
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Steel is one of the most common hot forging materials. Carbon steel, alloy steel, and stainless steel can all be machined by the hot forging process to improve their strength and plasticity.
- Magnesium alloy has good strength and lightweight characteristics and is often used in the aerospace field. Magnesium alloys AZ31 and AZ61 have excellent performance in the hot forging process.
- Aluminum alloys are also commonly used in hot forging. Aluminum alloy 6061, 2024, and 7075 series are widely used in aerospace, automotive manufacturing, and construction engineering.
- Titanium alloys have excellent strength and corrosion resistance. Pure titanium and titanium alloys (such as Ti-6Al-4V) are often processed by hot forging and are used in aviation, medical, and chemical industries.
- Nickel alloys are widely used in high-temperature and corrosive environments. Nickel-based superalloys, such as Inconel 718, can obtain the desired mechanical properties through hot forging processes.
The benefits of metal forging
A lot of valve seats, spools, stems, and other valve seats, spools, stems, etc., use metal forging. What are the benefits of metal forging parts? Forging valve bodies are also commonly used in high-pressure and strong corrosion alloy valves.
High strength: The process of hot forging encourages grain refinement and crystallization, which gives the material strength and uniformity while lowering part-to-part variation. Particle flow following the contours of the body lessens fatigue and frequent failures.
Structural integrity: Forging creates a cogent metallographic structure that ensures superior performance by removing internal flaws. Forgings ensure trouble-free and extended service life in areas of high stress and crystal corrosion.
Reliability – Structural integrity Forging eliminates internal defects and produces a coherent metallographic structure that guarantees excellent performance. Where stress and crystal corrosion are severe, forgings guarantee a long service life and trouble-free service.
MIM Parts vs Forged: A Comparison of Material, Weight, Tolerance, and Product Performance
When it comes to metal manufacturing processes, MIM (Metal Injection Molding) and forging are often compared. In this article, we will explore the differences between these techniques and their impact on material properties, weight limitations, tolerance requirements, and product performance.
FORGED PARTS
MIM PARTS
- Material: MIM involves the use of metal powders with an average particle size below 20µm, allowing for the production of intricate and finely detailed parts. On the other hand, forging uses solid metal blocks, enabling the creation of larger and heavier metal products.
- Weight: MIM is suitable for manufacturing smaller and lighter parts, typically ranging from 0.1g to 500g. In contrast, forging can handle significant weight, with products ranging from a few hundred grams up to an impressive 30,000kg.
- Tolerance: MIM requires strict control over metal powder preparation and injection processes, resulting in higher tolerance requirements for part dimensions. Complex-shaped MIM parts commonly fall within the 20mm to 30mm size range. Alternatively, forging has relatively lower tolerance requirements, as long as it does not compromise the overall assembly.
- Product Performance: MIM-produced parts offer excellent surface smoothness, aesthetic appeal, and moderate weight considerations. They are well-suited for precision components. On the other hand, forging enhances the mechanical properties of metal materials, significantly improving strength, toughness, and fatigue resistance. This makes forging the preferred choice for applications that demand high mechanical performance.
MIM TOLERANCE
In conclusion, the selection between MIM and forging depends on various factors such as desired weight, part complexity, and required mechanical properties. Understanding these differences can help optimize the manufacturing process for specific requirements and achieve the desired product performance.
When To Use MIM vs Forged
In the production of metal parts, MIM and forging techniques have distinct capabilities. Different products ought to select a better method. Metal forging is appropriate for basic metal components needing high strength requirements and is generally suitable for relatively large metal parts, whereas metal injection molding is particularly suitable for mass production of small structure complicated metal parts.
Comparison of other metalworking processes: