Powder Forging of Rapidly Solidified hi-Si Alloy with Back Pressure

Powder forging with a back pressure was investigated for production of automobile and compressor parts made of a rapidly solidified Al-Si alloy powder. Disk-shaped green compacts made of a rapidly solidified Al-Si alloy powder were hot forged, and hubs were formed by loading back pressure on their top. The influences of the back pressure and die temperatures on forgeabiliy and properties of parts made of a rapidly solidified Al-Si alloy powder were examined. This method was also applied to the production of a scroll part. The results of these studies are summarized as follows : 1. A back pressure on the hub top is very effective for consolidation and preventing crack formation in the hub. 2. When a back pressure tess than 98 MPa is applied, the forging pressure increases by the same amount of the applied back pressure. With more than 98 MPa, the forging pressure increases further due to an increased friction at the hub side. 3. Die temperatures higher than approximately 670k are needed in order to consolidate well the hub top without cracks.