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Impression-die forging is also called "closed-die forging". In impression-die forging, the metal is placed in a die resembling a mold, which is attached to an anvil. Usually, the hammer die is shaped as well. The hammer is then dropped on the workpiece, causing the metal to flow and fill the die cavities.
Impression-die forging has been further improved in recent years through increased automation which includes induction heating, mechanical feeding, positioning and manipulation, and the direct heat treatment of parts after forging. One variation of impression-die forging is called flashless forging, or true closed-die forging.
The tools that are used, dies and punches, come in many different shapes and sizes, as well as materials. Examples of these shapes are flat and v-shaped which are used for open-die forging, and single or multiple-impression dies used for closed die forging. The designs for the dies have many aspects to them that must be considered.
A modified die casting machine is used to inject the semi-solid slurry into reusable hardened steel dies. The high viscosity of the semi-solid metal, along with the use of controlled die filling conditions, ensures that the semi-solid metal fills the die in a non-turbulent manner so that harmful porosity can be essentially eliminated.
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These are resistance forge-welding techniques where the press or die is electrified, passing high current through the alloy to create the heat for the weld. [25] Shielded active-gas forge-welding is a process of forge welding in an oxygen-reactive environment, to burn out oxides, using hydrogen gas and induction heating .
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