At Sachin forge, we employ the most efficient and reliable technology. To maintain Optimum Grain Structure, Surface finish and Physical properties of the alloy consistent. The variables involved such as temperature , pressure and duration of ageing in heat treatment should be kept precise and as per the standards. This ensures that the forged parts will function as per the design capacity.
Each order we receive is worked upon with the almost care and attention to detail.We also accommodate the request made by our customers and have the capabilities to install and operate additional processes.
Aluminium Forging
Of all structural metals and alloys, aluminium alloys are the most readily forged to precise intricate shapes. There are a number of reasons for this: aluminium alloys are ductile; they can be forged with dies heated essentially to the same temperatures as the work piece; they do not develop scale during heating; and they require lower forging pressures.
Forging temperatures are very low, being below incandescent temperatures. Thus, temperature controls and furnace construction for aluminium are different from those used with ferrous materials. Radiation type (infra red) sensors are increasingly used for measuring billet surface temperatures. Most indirect fired, re circulating air furnaces are controlled by internal thermocouples.
| Forging Temperatures for aluminium Alloys (°F) | |||||
|---|---|---|---|---|---|
| Alloy | Solidus Temperature | Solution Temperature | Hammer | Mechanical Press | Hydraulic Press |
| 5083 | 1090 | Not HT | 700-850 | 750-900 | 750-950 |
| 2014 | 945 | 850 | 700-800 | 750-850 | 750-875 |
| 2025 | 970 | 890 | 800-875 | 800-900 | 800-900 |
| 6061 | 1080 | 920 | 700-875 | 700-900 | 700-925 |
| 7075* | 890 | 800 | 675-775 | 700-800 | 700-850 |
| 7050* | 900 | 830 | 700-800 | 700-820 | |
| 7079* | 900 | 850 | 700-800 | 700-825 | 700-850 |
| *These alloys are not usually forged in hammers due to internal temprature increases with a lower melting temprature | |||||
Die temperature ranges for the forging of aluminium alloys
| Forging process/equipment | Die temperature | |
|---|---|---|
| C | F | |
| Open-die forging | ||
|---|---|---|
| Ring rolling | 95-205 | 200-400 |
| Closed-die forging | ||
|---|---|---|
| Hammers | 95-150 | 200-300 |
| Mechanical presses | 150-260 | 300-500 |
| Hydraulic presses | 315-430 | 600-800 |
| Alloy Designation | Temper | Mechanical Properties(Min. Values) | ||||
| Numerical | Conventional | R Mpa | Rp 0,2[Mpa] | A5[%] | HB | |
| EN AW 2011 | EN AW-AlCu6BiPb | T6 | 340 | 230 | 10 | 100 |
| EN AW 2014 | EN AW-AlCu4SiMg | T6/T651 | 440 | 380 | 6 | 120 |
| EN AW 6061 | EN AW-AlMg1SiCu | T6 | 280 | 240 | 7 | 85 |
| EN AW 6082 | EN AW-AlSi1MgMn | T6 | 310 | 260 | 6 | 90 |
| EN AW 7075 | EN AW-AlZn5,5mgCu | T6/T73 | 500/445 | 425/375 | 7.0/6.0 | 135/120 |
Flashless Technology
Our core strength lies in advanced technologies and innovations undertaken in the entire process. FLASHLESS forging technology is the standard Sachin Forge. In fact, more than 80 percent of all products forged by Sachin Forge utilize this advanced technology. With Flashless forging, you'll benefit with:
- Less raw material
- Less cost
- 0.5 TO 1 degree draft on the O.D.
- Tighter tolerances
- Eliminated balance and interrupted cuts
- Net and Near-Net
Net and Near-Net technology is the perfect process for cut-tooth gear manufacturing. You'll use less raw material, reduce your finishing operations and reduce your shipping costs. Near-Net manufacturing utilizes a hot forged process for a smooth finish.
Backward Aluminium Extrusion
Backward impact extrusion is a method of forming hollow metal parts by striking a metal billet (or disk), which is confined within a cylindrical or square die, so that the metal is forced upward into the space between the “hammer” (or punch) and the die. The gap between the punch and the inside of the die determines the wall thickness of the final component.
There are in fact two types of impact extrusion, forward extrusion and backward extrusion. Backward or indirect extrusion is used to make hollow shapes, because the punch is solid and thrusts the material around itself into the space between itself and the die. Backward impact extrusion gives the metal improved strength and rigidity after forming, to allow for thinner wall thicknesses which can help to minimize material use.
Trade Policy
The trade policy and procedures at Sachin Forge is Customer oriented at all steps. We respond to all customer enquiries within 3 working days. The development of profile components is undertaken within 2 weeks, while that of round components is done in 7 days from the receipt of Purchase Order.
Quality Control
Quality standards
Sachin Forge is an ISO 9001:2015 certified company. In addition we also have ADWO and PED certifications from TUV NORD.
It’s been our constant effort that each customer specification is carefully transformed into a cost-efficient reality and every component, which we create, is a statement in itself towards our overall dedication to craftsmanship.
At Sachin Forge, we are committed to achieve the highest level of customer satisfaction through continuous improvement in our products and services. We have implemented SPC to minimize rejections during the manufacturing process. We take every possible step to identify necessary and avoidable costs and set targets to reduce avoidable costs to the minimum.
Our quality policy aims at achieving the following:
- Exceeding customer requirements over and over again
- On time deliveries
- Continuous improvements in our processes and controls in all domains of business
- Constant monitoring of input quality from our suppliers