A near-net forming process, FORMCAST™, has been developed with the capability of forming components from ductile metals into complex three dimensional shapes. Excellent as-formed mechanical properties are achieved as the material is under constant, high pressure during the forming process generating significant levels of work hardening. FORMCAST™ shares characteristics with other conventional processes (i.e., forming, casting, and extrusion), yet eliminates porosity, the need for draft angles, non-uniform material properties, excessive scrap, and shrinkage concerns.
This paper will supply information to allow the comparison of FORMCAST™ to other processes. Items discussed will include the mechanics of the forming process, materials and that can be formed, as-formed material properties, characteristics, dimensional capabilities, and the process economics.