Analysis of the Effect of the Elongation Operation on the Welding of Internal Metallurgical Discontinuities

This article discusses the results of our research into the effect of elongation on the welding of internal metallurgical discontinuities for two different geometrical shapes of a model feedstock of a selected magnesium alloy. Model discontinuities, specifically those of the metallurgical void type, were placed in various local zones of the modelled feedstock to check the influence of their location on their welding. The numerical modelling was carried out using the Forge(®)NxT2.1 application based on the finite element method. The results of the numerical tests were verified in laboratory conditions using the Gleeble simulator of metallurgical processes. Based on this research, it was found that the geometric shape of the feedstock material and the location of internal metallurgical discontinuities have a significant impact on the welding of discontinuities. The optimal values of the main process parameters of the elongation operation in flat dies were also determined for use in individual forging stages in order to eliminate internal metallurgical discontinuities. On the basis of the numerical studies carried out and their verification under laboratory conditions, it was concluded that a relative draft equal to 35% should be applied to weld the metallurgical discontinuities, which would result in a favorable hydrostatic pressure distribution within the discontinuities.