Evaluation of thixoforging process for steering piston production as possible alternative to hot forging

In this paper, the evolution from hot forging to thixoforging process is presented. A real-case study, involving a steel-made steering piston production by thixoforging technique is evaluated. The transition between the traditional forging process and the new one involves several transformations and presents difficulties mainly due to the high working temperature. The targeted thixoforging technology allows obtaining near-net-shape components with good surface quality and mechanical properties provided along with a substantial reduction in material quantity, and implicitly of the involved amount of energy. According to the reported Finite Element based simulation results, the thixoforged component will weight 9.3 kg, which is 1 kg less than that obtained by hot forging technique. The total material saving at the starting billet level compared to the hot forging process corresponds to 2.3 kg