Insights · Materials
Aluminum Alloy Forging for New Energy Vehicles and Industrial Equipment
· Updated ·3 min read
Every kilogram counts in an electric vehicle. A lighter car goes further on the same battery, and a lighter suspension improves ride and handling. That is why demand for forged aluminum parts is growing in new energy vehicles, and in industrial equipment that has to move fast, run efficiently or resist corrosion.
Why aluminum?
Aluminum has about one third of the density of steel (about 2.7 g/cm³ against about 7.85 g/cm³). Heat-treated forging alloys reach strengths that make them a real alternative to steel in many structural parts, while aluminum also resists corrosion without heavy coatings.
Why forged rather than cast?
Aluminum parts can be cast, extruded, machined from plate or forged. For parts that carry high or repeated loads, forging is usually the best choice:
- No porosity. Forging closes internal voids that can start fatigue cracks in castings.
- Grain flow follows the part. The strongest direction of the material runs along the load path.
- Higher strength from the same alloy. That allows thinner, lighter sections.
- Less material wasted than machining the part from solid.
Common forging alloys
| Alloy | Typical tensile strength (T6) | Typical uses |
|---|---|---|
| 6061 / EN AW-6061 | about 310 MPa | Structural parts, brackets, hubs, brake calipers |
| 6082 / EN AW-6082 | about 330 MPa | Suspension and chassis parts, couplings, clamps |
| 7075 / EN AW-7075 | about 570 MPa | Highly loaded parts, climbing hardware, motorsport parts |
| 2014 / 2A14 | about 480 MPa | Parts at raised temperatures, such as compressor wheels |
Values are typical figures for the T6 temper; the guaranteed minimum depends on the standard, the forging and its section size.
Typical forged aluminum parts
In new energy vehicles and industrial equipment, forged aluminum is used for:
- suspension and chassis parts such as control arms and steering knuckles
- brake calipers and wheel hubs
- compressor wheels and scroll compressor parts for air conditioning and thermal management
- pump bodies, valve parts and transmission components in industrial machinery
How Aviaforge forges aluminum
Aviaforge has focused on aluminum forging for over 35 years:
- Equipment: seven servo-electric screw press forging lines, the largest a 1,600-ton press
- Processes: hot forging, precision near-net-shape die forging (about 30% better material utilization) and isothermal forging (about 30% more uniform grain structure), suited to high-strength alloys
- Heat treatment: in-house T6 on an automated line
- Machining: CNC turning and milling, up to 5-axis machining for complex parts
- Inspection: fluorescent penetrant and X-ray testing, hardness testing, grain size and metallographic analysis, under an ISO 9001:2015 quality system
- Volumes: first prototypes within 30 days; production orders of 2,000 to 50,000 pieces, typically shipped in 5–7 weeks
For an example, see how Aviaforge replaced cast compressor wheel blanks with forged 2A14 aluminum for a European turbocharger supplier: read the case study.
Frequently asked questions
Is forged aluminum as strong as steel? Not alloy for alloy, but 7075-T6 forgings reach about 570 MPa, comparable to many structural steels, at about one third of the weight. For most parts the goal is the best strength for the weight, and there forged aluminum often wins.
Which aluminum alloy is best for forged automotive parts? 6082 and 6061 are the usual choice for suspension and chassis parts, as they combine strength, toughness and corrosion resistance. 7075 is used where strength matters most.
Can Aviaforge forge to my drawing? Yes. Send us your drawing, specification or sample and we will review it for forging, propose the alloy and process, and quote. Contact us.
