Design and optimization of an integrated casting-forging process for tin bronze valve bodies based on hot deformation behavior

IF 2.6 3区材料科学 Q2 ENGINEERING, MANUFACTURING

International Journal of Material Forming Pub Date : 2025-08-04 DOI:10.1007/s12289-025-01937-0

Chunge Wang, Yangbiao Zeng, Xiang Yan, Wen Liu, Chaoyang Wang, Binfeng Wang, Meiling Zhou, Zhu Xiao

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引用次数: 0

Abstract

Tin bronze valve bodies are widely used in fluid control systems requiring high corrosion resistance. However, conventional casting introduces defects such as porosity, segregation, and “sweating tin,” while forging is limited by the alloy’s thermal brittleness and difficulty in forming complex geometries. These issues hinder the integration of structural complexity with high mechanical performance. To address this, a novel integrated casting-forging process is proposed, consisting of three stages: casting, thermal holding at forging temperature, and hot forging. Using C83600 tin bronze, hot compression tests were conducted to construct a processing map and determine the optimal hot working parameters. A coupled simulation framework based on THERCAST and FORGE was developed to model solidification, homogenization, and forging, validating the feasibility of both bidirectional and triaxial extrusion schemes. Experimental trials confirmed that forging the billet while hot enabled seamless process transition, enhanced stability, and reduced cycle time. The resulting valve bodies exhibited significantly improved density of 9.25 g/cm³ and mechanical properties, hardness of 169 HB. This integrated approach demonstrates clear technical feasibility and practical potential for high-performance tin bronze component manufacturing.

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基于热变形特性的锡青铜阀体铸锻一体化工艺设计与优化

锡青铜阀体广泛应用于对耐腐蚀性要求较高的流体控制系统中。然而，传统的铸造会引入气孔、偏析和“出汗锡”等缺陷，而锻造则受到合金的热脆性和难以形成复杂几何形状的限制。这些问题阻碍了结构复杂性与高机械性能的整合。为了解决这一问题，提出了一种新的铸锻一体化工艺，包括三个阶段：铸造、锻造温度下的热保温和热锻造。以C83600锡青铜为材料，进行了热压缩试验，建立了加工图，确定了最佳热加工参数。开发了基于THERCAST和FORGE的耦合模拟框架，对凝固、均匀化和锻造过程进行了模拟，验证了双向和三轴挤压方案的可行性。实验证实，热锻坯料实现了无缝工艺过渡，提高了稳定性，缩短了周期时间。结果表明，阀体的密度显著提高，达到9.25 g/cm3，力学性能，硬度达到169 HB。这种综合方法为高性能锡青铜部件制造提供了明确的技术可行性和实用潜力。

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来源期刊

International Journal of Material Forming ENGINEERING, MANUFACTURING-MATERIALS SCIENCE, MULTIDISCIPLINARY

CiteScore

5.10

自引率

4.20%

发文量

审稿时长

>12 weeks

期刊介绍： The Journal publishes and disseminates original research in the field of material forming. The research should constitute major achievements in the understanding, modeling or simulation of material forming processes. In this respect ‘forming’ implies a deliberate deformation of material. The journal establishes a platform of communication between engineers and scientists, covering all forming processes, including sheet forming, bulk forming, powder forming, forming in near-melt conditions (injection moulding, thixoforming, film blowing etc.), micro-forming, hydro-forming, thermo-forming, incremental forming etc. Other manufacturing technologies like machining and cutting can be included if the focus of the work is on plastic deformations. All materials (metals, ceramics, polymers, composites, glass, wood, fibre reinforced materials, materials in food processing, biomaterials, nano-materials, shape memory alloys etc.) and approaches (micro-macro modelling, thermo-mechanical modelling, numerical simulation including new and advanced numerical strategies, experimental analysis, inverse analysis, model identification, optimization, design and control of forming tools and machines, wear and friction, mechanical behavior and formability of materials etc.) are concerned.