High demands are placed on the microstructure and performance of magnesium (Mg) alloy characteristic forgings since they are utilized as significant lightweight structural components in harsh environments, need to withstand high loads and experience severe surface wear. There is a big difference between Mg alloy profiles and characteristic forgings not only in the die structure, but also in the forming process, so summarizing and reviewing the forming process of Mg alloy characteristic forgings has important engineering significance for the development of lightweight today. This paper compares the differences in the forming processes of Mg alloy profiles and forgings and reviews the recent developments in the forming processes of Mg alloy characteristic forgings. The authors take the cup-shaped pieces as the starting point, extend it to other forgings and localized forming processes, and systematically discuss and analyze its advantages and disadvantages from the improvement of die structure and the exploration of the forming process. Finally, from the perspective of future forming and industrial application of Mg alloy forgings, the development direction and prospect of Mg alloy characteristic forgings are analyzed and summarized. It is anticipated that this review can give new cues to the forming processes of Mg alloy forgings. 

Review on forming process of magnesium alloy characteristic forgings

Analysis of solid-state welding in extruding wide aluminium hollow profiles using a new three-container extrusion system

Aluminum alloy has the characteristics of light weight, high strength, corrosion resistance, easy forming, etc., and is widely used in manufacturing industry. The extrusion speed of aluminum alloy rim is not uniform, which affects the mechanical properties of the product. In order to solve these 1problems, the finite element analysis model of hot extrusion of aluminum alloy profiles was established in HyperXtrude software. The influences of different bar diameters, hot extrusion velocity, bar preheating temperature, die temperature and extrusion cylinder temperature on velocity difference and maximum extrusion pressure at the exit were analyzed. The results show that the designed hot extrusion rim die meets the requirements of strength and deformation, and the best extrusion process parameters of 7075 aluminum alloy rim profiles in improving profile quality and reducing energy consumption are obtained by Taguchi test grey correlation method. 

Optimization of hot extrusion process parameters for 7075 aluminum alloy rims based on HyperXtrude

The review summarizes high-energy processing techniques applied for additive manufacturing and surface engineering of cemented carbides and cermets, including laser, electron, and ion beams, as well as plasma and electric discharges. The motivation for writing the review has been the fact that numerous papers have been published in these areas of science, but prospects for such studies in terms of their industrial implementations are unclear at present. In this way, the authors' goal has been to report achievements, challenges and gaps in knowledge for a more meaningful drawing of further research roadmaps. The review includes classifications of up-to-date cemented carbides and cermets in accordance with their compositions, fabrication methods, microstructure, functional properties and typical operating conditions. Then, some patterns of the evaluation of their microstructure and key characteristics are summarized. After that, achievements and challenges of laser and electron-beam additive manufacturing procedures are overviewed. Another topical section is devoted to surface engineering by both conventional methods and high-energy processing procedures. The authors have concluded that the key challenges are difficulties in simultaneous processing of both hard and binder phases without deteriorating their properties in the formed composites, as well as great residual stresses, causing the formation of cracks. To solve these issues, computer simulation methods, implemented for additive manufacturing and surface processing of metallic products, should be adapted for such composite materials. Also, a comparative economic evaluation of the return on investment in such innovative processes should be done for focusing on promising research directions. 

A review of high-energy processing techniques applied for additive manufacturing and surface engineering of cemented carbides and cermets

Effect of grain size and second phase on the corrosion behavior of MIG-welded Al–Mg–Si–Mn–Cr alloy

Abnormal grain growth behavior and mechanism of 6005A aluminum alloy extrusion profile

Effects of billet heating temperature and extrusion speed on the microstructures and mechanical properties of the longitudinal welds in aluminum alloy profiles with complex cross-section

Al-Li alloys suffer from a narrow processing window. The hot deformation behavior of the ramp heating homogenized 2195 Al-Li alloy was investigated by hot compression test in the temperature range of 300-500 ℃ and strain rate range of 0.01-10 s-1, and the strain compensated Arrhenius constitutive relationship model and processing map of the alloy were established. The laws of Zener-Hollomon parameters on the age-hardening response and quenching sensitivity of the deformed alloy were analyzed. The quenching precipitation mechanism of the deformed alloy were revealed. The results showed that the hardness of the aged alloy tends to increase first and then decrease with increasing Z parameter, while the quenching sensitivity tends to decrease first and then increase. The quench-induced phases are precipitated under the induction of incoherent Al3Zr dispersoids within recrystallized grains. The boundary angle would affect the quenching precipitation behavior. It was also found that the types and amounts of second phases are significantly different between the homogenized and hot-deformed samples under slow cooling rate. The ramp heating homogenized 2195 Al-Li alloy after hot deformation at temperatures of 455-500 °C and strain rates below 1 s-1 possesses a lower flow stress, higher age-hardening response and smaller quenching sensitivity. 

Investigation on hot deformation behavior and quenching precipitation mechanism of 2195 Al-Li alloy

The refining of aluminum scraps commonly employs nitrogen-fluxes to eliminate impurities. However, the aluminum nitride (AlN)generated by the reaction between nitrogen and the aluminum melt, along with residual fluxes, contribute to low cleanliness of the recycled aluminum melt and pose difficulties for the disposal of secondary aluminum dross (SAD) . Our innovative research has resulted in the recycling of aerospace-grade clean aluminum alloy melts. The results indicate that the argon bubble floating process adsorbs inclusions and hydrogen, achieving an aerospace-grade ultra-clean melt. The solid-liquid interface between the tube wall and the melt provides a diffusion channel for hydrogen atoms, and the bubbles rising up along the wall lead to a higher hydrogen content in the melt. The argon refining dross is primarily composed of Al and Al2O3, which can be recycled as a raw material for aluminum electrolysis. Argon refining can decrease the hydrogen content and the number of inclusions with particle size ≥40μm in the recycled aluminum melt to the level of aerospace aluminum alloy melt. Nonetheless, the particle size ≥20μm remains 1.5-2.5 times that of primary aluminum. 

Sustainable recycling of aerospace-grade ultra-clean 7050 aluminum alloy melts through argon refining without secondary aluminum dross generation

The grains at the longitudinal weld in porthole extrusion profiles are more prone to abnormal growth during solid solution treatment, leading to a decline in mechanical properties. To improve the microstructure and enhance the mechanical properties at the longitudinal weld in profile, the precipitation behavior of the dispersoid in 2195 Al-Li alloy with different homogenization heating rates was studied. The impact of dispersoid morphology and distribution on grain structure and mechanical properties at the longitudinal weld was elucidated. The results indicated that the ramp heating homogenization treatment significantly promoted the precipitation of fine Al3Zr dispersoids, which effectively hindered the abnormal growth of grains within the low plastic deformation zone at the longitudinal weld and reduced the width of the coarse grain zone. The tensile strength and elongation of the ramp heating homogenized (RH) profiles after water quenching and aging were higher than those of the fast heating homogenized (FH) profiles. It was also found that the incoherent Al3Zr dispersoid within the recrystallized grains of the profile was prone to induce the precipitation of quench-induced phases. Due to the reduction of recrystallization fraction at the longitudinal weld in RH profile, the precipitation of quench-induced phases was inhibited. The strength of the air-quenched and aged RH profile was higher than that of the FH profile. It can be concluded that the extrusion process using the RH billet can improve the microstructure and mechanical properties at the longitudinal weld in 2195 Al-Li alloy profile. 

Effect of strain and dispersoids on abnormal grain growth, precipitation behavior and mechanical properties at longitudinal weld in Al-Li alloy profile

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