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Four types of defects that occur in the forging of a 2024 aluminum-alloy matrix reinforced with 25 volume percent stainless steel wires are characterized, and forming limit criteria for the prediction and prevention of the two major types are established. These criteria, presenting allowable stress states during deformation processing, are combined with an analysis of flow of metal in the forging process to provide design guidelines for the forging of an airfoil shape from rectangular preforms.
The design guidelines developed, based on the forming limit criteria and metal flow analysis, demonstrate a systematic approach to the design of processes for forging complex shapes from metal-matrix composites. Utilizing this approach, process parameters (preform geometry, die configuration, friction) can be evaluated in the development of processes for forging sound, complex shapes from composite materials.
workability, forging, composites, compression, forming limits, ductile fracture, formability
Associate professor, Middle East Technical University, Ankara,
Professor, University of Pittsburgh, Pittsburgh, Pa.