What are the core roles of hot forgings in the production of auto parts?
As a key technology in the modern automotive industry, the hot forging process greatly improves the mechanical properties and reliability of parts through high-temperature plastic deformation. Hot forgings are widely used in core components such as engines, transmission systems, chassis, etc. due to their high strength, light weight and fatigue resistance, and have become an important guarantee for automobile safety and performance.
Technical advantages and application scenarios of hot forging technology
Key engine components
1、Application of hot forgings: Crankshafts, connecting rods, piston pins and other core components need to withstand extreme high temperature and high pressure environments. After hot forging of 42CrMo steel, the tensile strength can reach more than 600MPa, and grain refinement significantly improves fatigue resistance.
Process value: By precisely controlling the forging temperature (1200-1250℃) and die pressure, hot forgings can eliminate casting defects and ensure long-term stable operation of the engine.
2、High-load components of transmission system
- Application of hot forgings: Transmission gears, transmission shafts, etc. are formed by hot forging process. The hardness of the tooth surface after carburizing and quenching reaches HRC58-62, and the wear resistance is more than 30% higher than that of traditional castings.
- Process breakthrough: Combined with closed die forging technology, hot forgings achieve near-net forming, reduce material waste, and reduce unit cost by 15%-20%.
3、Chassis and suspension lightweight components
- Application of hot forgings: Hot forgings such as aluminum alloy (such as 6061-T6) steering knuckles and control arms are 40% lighter than traditional steel parts, while maintaining the same strength and rigidity, helping to improve the endurance of new energy vehicles.
- Process innovation: Multi-directional forging technology enables complex structures to be formed in one piece. For example, the rear floor of Tesla Model Y is forged by a 6,000-ton press, reducing 1,600 welding points.
Industry challenges and future trends of hot forging process
1、Technology upgrade direction
- Die life optimization: Through TiAlN coating and intelligent cooling system, the life of H13 steel die is increased from 10,000 times to 30,000 times.
- Green manufacturing: Induction heating technology reduces energy consumption by 30%, and aluminum chips remelting achieves a waste recycling rate of over 95%.
2、Emerging field expansion
- Battery and motor components: High-strength aluminum alloy hot forgings are used in battery pack brackets and motor housings, taking into account lightweight and collision safety.
- Composite material forging: In the carbon fiber reinforced aluminum matrix (CFRP/Al) hot forging process test, the target strength is 50% higher than that of traditional materials.
Conclusion: Hot forgings drive automobile manufacturing innovation
From traditional fuel vehicles to the new energy era, hot forging technology has always been the core technology for high-performance automotive parts. Through material innovation, intelligent shape control and green production, hot forgings will continue to break through the limits of lightweight and strength, provide solid guarantees for automobile safety, energy saving and reliability, and lead the industry to transform towards high efficiency and low carbon.
