Comparison of unextruded Air Slip direct chill cast 6061 ingot with bar stock extruded from conventional direct chill cast 6061 ingot

Air Slip direct chill cast 6061 small diameter ingots (Direct Forge) were compared with 6061 extruded bar stock. The T6 mechanical properties were compared for both the Direct Forge ingot and the extruded bar stock, as well as cold impact extruded cylinders produced from Direct Forge small diameter ingot and extruded stock. It was found that the tensile and fatigue properties of Direct Forge ingot and cylinders from this ingot were significantly superior to those of extruded stock and cylinder produced from this stock The improved properties are a result of higher solidification rates leading to smaller alloy-constituent dispersed particles and, thus, the production of smaller and more stable grain sizes. Direct Forge has the additional advantages of (a) not requiring hot or cold work prior to forming impacted extruded or forged parts, (b) being utilized in the T6 temper without any prior deformation, (c) having isotropic and consistent properties, (d) not requiring machining to remove surface segregation or defects, and (e) having more consistent and refined grain sizes.