Numerical and Experimental Analysis of the Forging of a Bimetallic Crosshead

Abstract

Abstract The automobile sector has been making increasing efforts to reduce the weight of automobiles, aiming at mitigating pollutant gas emissions. The use of innovative concepts, such as bimetallic components, has become attractive because it makes it possible to increase the strength-to-weight ratio of the components. In this study, the hot forging of a bimetallic crosshead is investigated. In the process, a billet with a cylindrical core of the magnesium alloy AZ61 is enclosed with a hollow cylinder of the aluminum alloy AA 6351 and forged at 400°C. The objective is to reconcile the low density of Mg alloys with the high corrosion resistance of Al alloys. In parallel, a finite element analysis of the process was carried out.