Casting and Forging for manufacturing of components with tailored geometry and strength - CastForge

Purpose and goal

The aim was to identify the potential of a new production method where components are produced by partial forging on ductile cast iron. The project has indicated good forgeability and improved fatigue strength and has identified several automotive components with potential for CastForging. The project has shown that CastForging has a great potential to fulfill FFI´s program objectives for sustainable production technology like e.g. ´Efficient and flexible production´, ´Lightweight materials and new processes´ and ´Environment neutral´ production and optimized processes´.

Results and expected effects

The project indicates good forgeability, improved robustness of static strength and increased fatigue strength. It proved to be possible to simulate CastForging. Several traditional cast and forged components were identified with a high potential for CastForging. CastForging can reduce subsequent operations, achieve weight reduction, increase strength and reduce costs. The method leads to elimination of faulty parts, lower material consumption with at least 30 % and energy consumption with at least 20 % and reduces carbon emissions.

Approach and implementation

The work was carried out in the form of literature studies, production of test pieces in ductile cast iron, practical forging tryouts with different degrees of deformation at different temperatures, tensile testing, fatigue testing, initial tests with CastForging simulation, identification of possible components and estimation of potential energy, material and cost-reductions. The analysis was based on practical experiments and inspiring discussions with the participating companies, Scania CV AB, Volvo trucks AB and Igelfors Bruks AB as well as IVF and SWECAST.