A novel processing route was developed to produce automotive parts using an aluminium TiB_2 composite by casting to near-net-shape,, and then one-step forging. The composite was formed by a salt reaction in the molten alloy, resulting in well distributed, sub micron-sized particles of TiB_2. This process offers the benefits of reduced cost and improved properties. Using a suspension part as a case study, both experimental and simulation results are presented. The accelerated implementation of this route was facilitated by linked casting and forged software. Constitutive equations and microstructural models were developed to account for the influence of the particulate addition.
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