Advantages of the strength of aluminum alloy forgings? Application in electric bicycle
Old Wang the Forging is a senior aluminum alloy forging expert at Xinpingfu, with over 20 years of experience providing high-performance forged parts to electric bicycle manufacturers worldwide. He consistently emphasizes that for an electric bicycle to travel far, ride stably, and last long, the strength and lightweight of its key components are indispensable. Today, Old Wang the Forging will discuss the significant advantages of aluminum alloy forgings and their practical applications in electric bicycles.
Advantages of aluminum alloy forgings
Old Wang the Forging believes that the biggest advantage of aluminum alloy forgings is the “grain streamline” structure. By pressing the aluminum alloy into the mold at high temperature and pressure, the grains inside the metal are stretched and arranged in the direction of the force, forming a dense, porous-free structure.
Specific benefits include:
High strength and light weight: The tensile strength can reach more than 500–600 MPa, but the density is only 2.7g/cm³, which can effectively reduce the weight of the car and improve the endurance and handling.
Strong fatigue and impact resistance: Electric bicycles have to withstand road vibrations, starting brakes, and heavy riding every day, and the forged parts can significantly extend the service life.
High temperature and corrosion resistance: suitable for high-temperature environments around the battery and near the motor, and the surface has a better rust prevention effect after anodizing.
Suitable for mass production: near-net molding reduces waste and costs more reasonably.
Common materials for aluminum alloy forgings
Old Wang the Forging generally recommends the following three materials to e-bike customers:
6061-T6: Moderate strength (about 310 MPa), good corrosion resistance, easy anodizing, suitable for handlebars, stems, pedals and other daily components.
6082-T6: Higher strength (≥ 340 MPa) and excellent fatigue performance for frame structures and swingarms.
7075-T6: Ultra-high strength (up to 572 MPa) for the most stressed parts such as motor holders, cranks, and cranks.
“Old Wang the Forging” will help choose the most suitable alloy according to the customer’s endurance, load, budget and other needs.
Comparison with CNC machining and die casting
“Old Wang the Forging” uses the following table to help you visually compare the three processes:
| Project | Aluminum alloy forging | CNC machining | aluminum die casting |
| Strength | Highest | Medium | Low |
| Fatigue resistance | Excellent | Good | Poor (prone to porosity) |
| Impact resistance | Excellent | Good | Average |
| Weight Control | Optimal (Light and Strong) | Good | Average |
| Suitable for batch production | Medium to high batch production | Small batch production | Prototype ultra-high volume |
| Mold cost | Medium (One-time Use) | Low | High |
| Internal defects | Almost impossible | Microcracks present | Common defects include porosity and shrinkage |
“Old Wang the Forging” suggests that forging should be the preferred method for important structural components of electric bicycles (such as motor mounts, frames, and cranks); CNC machining can be used in the prototype stage, while die casting can be considered for ordinary non-load-bearing shell components.
Application in electric bicycles
Old Wang the Forging supplies key forged components for electric bicycles, including:
- Motor Mounts
- Battery Mounts
- Frame Components
- Crank Arms & Chainrings
- Pedals
- Stem & Handlebars
- Swingarm & Lugs
- Wheel Hubs
These forging parts make e-bikes lighter, stronger, and more durable, making them especially suitable for urban commuting, heavy-duty riding, and mountain biking.
Mold cycle
Old Wang the Forging promises: Mold development for aluminum alloy electric bicycle parts typically takes only 3–4 weeks. Once the mold is complete, qualified samples will be sent to the customer for testing and confirmation as soon as possible.
In high-volume production, the unit cost is low, delivery is fast, and the initial investment in molds can be recovered quickly.
Old Wang the Forging hopes that this article will help more electric bicycle manufacturers understand the true value of forging technology. If you are looking for lighter, stronger, and more reliable aluminum alloy forged parts, feel free to send your drawings or requirements to Old Wang the Forging at Xinpingfu, and we will provide professional advice and customized quotes.
Feel free to contact us anytime! Safe riding starts with choosing the right parts.
