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China has become a primary power in aluminum forging
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- Time of issue:2019-11-27 21:27
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(Summary description) Free forgings and die forgings are an important class of stressed structural parts and high-precision technology products. China has become the world’s primary power in aluminum forging production. Southwest Aluminum (Group) Co., Ltd. and Northeast Light Alloy Co., Ltd. produce 5m and The 9m-class large forged ring not only meets the needs of the development of China's aerospace industry, but also batches of other aluminum alloy forgings are installed on thousands of Boeing planes. The parts are qualified and there has never been a quality accident.
China has become a primary power in aluminum forging
(Summary description) Free forgings and die forgings are an important class of stressed structural parts and high-precision technology products. China has become the world’s primary power in aluminum forging production. Southwest Aluminum (Group) Co., Ltd. and Northeast Light Alloy Co., Ltd. produce 5m and The 9m-class large forged ring not only meets the needs of the development of China's aerospace industry, but also batches of other aluminum alloy forgings are installed on thousands of Boeing planes. The parts are qualified and there has never been a quality accident.
- Categories:Company News
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- Time of issue:2019-11-27 21:27
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Free forgings and die forgings are an important class of stressed structural parts and high-precision technology products. China has become the world’s primary power in aluminum forging production. Southwest Aluminum (Group) Co., Ltd. and Northeast Light Alloy Co., Ltd. produce 5m and The 9m-class large forged ring not only meets the needs of the development of China's aerospace industry, but also batches of other aluminum alloy forgings are installed on thousands of Boeing planes. The parts are qualified and there has never been a quality accident.
As of 2015, China has about 40 die forging machines ranging from 30MN to 500MN, including 2 units of 300MN, 3 units of 400MN, and 1 unit of 500MN. The world’s king of forging presses, designed and manufactured by ourselves, is a 800MN die forging machine. It has also been put into production, and the world's largest aluminum, magnesium, titanium and other alloy forgings will be forged. In 2014, the production capacity of China's aluminum forgings was approximately 194kt (including wheel forgings).
The overview of China's aluminum and magnesium alloy forging industry in 2015 is shown in the table below, with a total production capacity of 194kt/a.
Typical Enterprise
1. Northeast Light Alloy Co., Ltd.
The forging workshop of Northeast Light Alloy Co., Ltd. (formerly known as Harbin Aluminum Processing Plant, codenamed No. 10 Factory) was completed and put into operation in 1961. It was China's first aluminum and magnesium alloy forging project. The main equipment was imported from the Soviet Union, and there was a 100MN die forging machine. , 1 set of 50MN die forging machine, 1 set of 30MN die forging machine, 1 set of 3MN free forging machine, 2 sets of profiling milling machines. The designed production capacity of forgings is 3.7kt/a, including 0.8kt/a for free forgings and 2.9kt/a for die forgings. More than 95% of the products are for aerospace and military use. Since the reform and opening up, aerospace products are still the main ones. However, general industrial forgings have increased significantly.
2. The first forging plant built by self-reliance-the die forging branch of the Southwest Aluminum Processing Plant
The die forging branch of Southwest Aluminum (Group) Co., Ltd. (formerly known as Southwest Aluminum Processing Plant, codenamed Plant No. 12) is the first aluminum and magnesium alloy forging production plant built by New China on its own initiative. It was put into operation on July 1, 1970. There is one 8-column vertical 300MN die forging hydraulic press and one 60MN free forging hydraulic press designed and manufactured by China First Heavy Machinery Manufacturing Co., Ltd. (then named Fulaerji Heavy Machinery Manufacturing Plant), with a forging production capacity of 24.5kt/a. There is also a 125MN horizontal hydraulic press, which squeezes blanks for large forgings on the one hand, and squeezes some large industrial materials on the other.
The Forging Branch of Southwest Aluminum (Group) Co., Ltd. is manufacturing a 100MN free forging machine, which will be put into production at the end of 2017 or the first half of 2018. The branch plant has provided more than 100,000 tons of high-quality forgings for the development of China's aerospace industry since 1970, and has also exported a considerable number of forgings to the United States, equipped with thousands of Boeing aircraft.
3. The largest aluminum forging plant in China to be put into operation-Nanshan Group Forging Company
The first phase of the forging company of the Nanshan Aviation Division of Shandong Nanshan Aluminum Co., Ltd. can be put into production in December this year or early next year. In terms of forging force, it is only 710 MN, which is much smaller than the 1200 MN of Second Heavy Machinery Manufacturing Co., Ltd. But it will be the most in terms of the number of aluminum forgings. Nanshan Aviation Division Forging Company has 4 forging presses, 2 die forging machines, one for each of 125MN and 500MN, imported from Siempelkamp, Germany.
In December 2012, Nanshan Forging Company ordered a 500MN hydraulic die forging machine from Sempalkham, which is the largest such machine made in Germany so far, with a bottom size of 4m×7m. In addition, there are two free forging machines, one each of 25MN and 60MN, which are imported from German Wipke Sidrich.
This forging machine can produce aluminum alloy forgings as well as titanium alloy forgings. The total investment of the project is more than 1.5 billion yuan, and the main products are aluminum alloy forging products required by aerospace, transportation, energy, power machinery, mining equipment and so on. The added value of aluminum alloy forgings is high. According to the price in 2013, the sales price is about 95,000 yuan/t. In 2016, Nanshan Aluminum was the aluminum enterprise with the most complete industrial chain in the world, and also the single aluminum enterprise with the largest production capacity. All enterprises-alumina plant, aluminum electrolysis plant, rolling plant, extrusion plant, forging plant , Self-provided power plants, deep processing plants, etc. are all reasonably distributed on a 20km×20km "aluminum industry" land. This 400km2 piece of land contains about 60% of China's 2015 production capacity of can materials, 12% double zero foils, 25% hard alloy strips, 40% die forgings, and 4% large-scale high-end industrial extrusion materials.
4. Xi'an Triangle Aviation Forging Company
Xi’an Triangle Aviation Forging Co., Ltd. is located in Yanlang District, Xi’an. It provides large forgings for Xi’an Aircraft Manufacturing Co., Ltd. It has the world’s largest single-cylinder precision die forging hydraulic press—400MN hydraulic press. Designed by a team of designers and jointly manufactured by China 22nd Metallurgical Corporation and Tsinghua University, it is the world’s largest single-cylinder steel wire winding hydraulic press. It was put into production in 2012. The products are mainly used for aircraft such as aircraft landing gears and high-temperature alloy turbine disks for engines. . The basic technical parameters are:
Total height, m 20
High above the ground, m 14
Deep under the ground, m 6
Total mass, t 3200
Working pressure, N/mm2 60
Workbench size, m 3.5×4.5
Maximum speed, mm/s 60
5. Alcoa Suzhou Large Wheel Forging Plant
Alcoa Wheels and Transportation Products Division (AWTP) announced in January 2013 that it would build a specialized wheel forging plant in Suzhou, China, for trucks, semi-trailers, and buses. This signifies that Alcoa's wheel product manufacturing, distribution, sales and service network in mainland China will be fully expanded. Alcoa holds the world's best aluminum alloy wheel technology, especially its surface treatment technology. It also has two fastener plants in Suzhou.
6. Kobe Steel (Suzhou) Aluminum Co., Ltd.
Kobe Steel (Suzhou) Aluminum Co., Ltd. is an automobile suspension forging plant built by Japan's Kobe Steel, Mitsui & Co., and Handa Trading Group with an investment of 2.5 billion yuan. They account for 60%, 25% and 15% of the shares, respectively. The forging production capacity is 10,000 pieces/a, which has been put into production in October 2014. This is actually an expansion project, adding a 60MN forging press.
7. Chung Sang Aluminum Co., Ltd.
Zhongxiang Aluminum Co., Ltd. is located in Liaoyang Economic Development Zone, Liaoning Province. It is an enterprise that forges flange bearings and wheels. It has a production capacity of 5 million pieces/a, a total investment of 1.8 billion yuan, and a forging press in the first phase. It was put into operation in September 2014. .
8. China Metallurgical 22nd Metallurgical Group Co., Ltd.
The 120MN multi-directional die forging machine independently developed by China Metallurgical 22nd Metallurgical Group Co., Ltd. on October 11, 2014 forged a super-hard aluminum alloy wheel with a diameter of 630mm and a mass of 65kg, which is 20% lighter than cast wheels. But its tensile strength is three times that of cast wheels. This kind of wheel is forged through two processes of pre-forging and final forging.
9. AVIC Heavy Machinery Co., Ltd.
In June 2015, the 160MN isothermal forging press of AVIC Heavy Machinery Co., Ltd.'s isothermal forging production line (Phase I) successfully completed the hot test in Xi'an. It is the current domestic isothermal forging press with the largest forging pressure, which will greatly promote aerospace. The development and production of aircraft and engine forgings is of great significance for China to break through the bottleneck in the development of aircraft and engine forgings.
160MN isothermal forging press (see picture) has the characteristics of precise controllable forging speed and displacement, which can meet the isothermal superplastic forming of special high-temperature alloys, titanium alloys, intermetallic compounds and other difficult-to-deformation alloy forgings for aviation. The design forging pressure of this 160MN isothermal forging press is 160MN, and the actual maximum forging pressure can reach 200MN, which can satisfy all current titanium alloy precision forgings of aircraft structure, as well as the isothermal precision die forging of hard-to-deform alloy discs and shaft forgings of engines. According to the theory of superplastic forming, under isothermal forging process conditions, the forging capacity of a 160MN press is equivalent to that of an ordinary forging press of 800MN~1000MN, and the quality of forgings is also greatly improved.
The second one-one of the largest forging bases in China
As of 2015, China Second Heavy Machinery Manufacturing Co., Ltd. has 4 forging machines, 2 free forging, 1 120MN and 160MN each, 400MN and 800MN die forging presses, thus becoming one of the world's largest forging bases. Possesses the world's largest 800MN die forging press, known as the "king of heavy equipment", and was put into production in January 2013. Designed by the team of Erzhong's deputy chief engineer Chen Xiaoci as the chief designer, Erzhong is self-manufactured and installed independently. The total height is about 42m, the aboveground is 27m, and the underground is 15m deep, which is equivalent to a 13-story building with a total weight of about 22kt. Any stepless pressure adjustment forging within 800MN pressure, the maximum die forging force can reach 1000MN, high synchronization accuracy, strong anti-eccentric load ability, and stepless pressure adjustment and speed adjustment can be realized.
From the application for the 800MN die forging press in 2003 to the trial production stage in April 2013, the demonstration was 5 years, and the construction was 5 years. It can be described as 10 years of grinding a sword. More than 1,000 people participated in the construction. Pursuing the dream, on the basis of absorbing, digesting, and re-innovating, Duozhong broke through the extreme manufacturing of super-large, super-long and super-heavy parts, realized the combination of the latest technology and inherent technology, and successfully developed the 800MN large-scale die forging press. China has become the country with the highest level of die forging equipment in the world. At present, only the United States, Russia, and France have similar equipment, the largest of which is Russia's 750MN die forging press.
The 800MN die forging press put into production will completely change China's long-term dependence on imports and the passive situation of being controlled by people for large die forgings. It is of great significance to realize the independent guarantee of large die forging products and opened a new historical course for China to become a manufacturing power. Since then, the most difficult to manufacture large parts of Chinese aerospace vehicles, ships, ships, and armored weapons, power generation, ocean engineering, west-to-east gas transmission, deep mining and other industries require the highest performance, the largest size, and the most complex structure. All the components can be precisely formed by 800MN die forging press.
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