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In aircraft forging, which consequence results when dies are improperly aligned?

A)Increased localized residual stress
B)Homogeneous grain structure refinement
C)Improved fatigue crack propagation
D)Reduced coefficient of thermal expansion

💡 Explanation

Improperly aligned dies cause asymmetric deformation during forging; this introduces uneven plastic flow activating the *Bauschinger effect*. Because the material yields differently in tension versus compression, localized residual stress increases. Therefore, the alignment errors are detrimental to the durability rather than beneficial through grain refinement.

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