Creating alloys is a complex business requiring precise control over a wide range of complex variables that need to be understood. We at Copper Alloys Ltd have a deep metallurgical understanding of these complex processes.

WROUGHT ALLOY CREATION

Wrought alloys start life in the foundry by being cast using our special vertical continuous casting process, or by being cast into weighty forging ingots. The forging ingots are cast using our Quiescent Teaming System, specially designed to fill ingot moulds with non-turbulent flow, avoiding the formation of harmful metal oxide films and inclusions. Solidification is controlled to ensure a good macrostructure free from secondary shrinkage and sufficient ingot top discard to fully remove the primary pipe which is the result of feeding solidification contraction.

THE CAST PRODUCT INTO WROUGHT PRODUCT

Converting the cast product into wrought product involves a controlled pre-heat to elevated temperature, where the material can be shaped whilst hot using a variety of possesses. These include press, hammer & rotary forging, strip and bar rolling, extrusion and closed die forging & ring-rolling. The resulting products include bars (round, flat, square), stepped shafts, boss forgings, rings, blocks and complex shapes closed-die forged shapes.

HOT FORMING PROCESSES

Hot forming processes are carefully controlling to ensure the cast structure is fully broken down into a fine uniform wrought structure. Wrought products have greater soundness and integrity compared with cast products and have a higher combination of mechanical strength and toughness. In the case of nickel aluminium bronze, the microstructure is less prone to selective phase attack compared with cast material.

3 Benefits of Forgings

Quicker & on-time delivery; risk of non-delivery reduced
High integrity - actual material properties are reported
Enhanced resistance to corrosion and general performance

3 Limitations of Castings

Actual component properties are unknown as reported properties come from separately cast test piece
Prone to metallurgical defects
No efficient method of volumetric inspection

2 Myths about Forgings

Forgings are more expensive
Due to the reliability of the production process, zero tooling costs and scalability of production, components made from forgings can be lower cost
Complicated shapes have to be castings
With modern CNC machining techniques, it is possible to machine surprisingly complicated components from solid blocks of forged material. A good example is this nickel-aluminium bronze forging, that was machined from solid. Previously it was two castings welded together.