Effect of die design on the welding quality during solid state recycling of AA6060 chips by hot extrusion

2013 ◽  
Vol 574 ◽  
pp. 163-175 ◽  
Author(s):  
V. Güley ◽  
A. Güzel ◽  
A. Jäger ◽  
N. Ben Khalifa ◽  
A.E. Tekkaya ◽  
...  
Keyword(s):  
Solid State ◽  
Hot Extrusion ◽  
Die Design ◽  
Welding Quality

Solid state recycling of aluminium AA6061 alloy chips by hot extrusion

2018 ◽  
Vol 6 (3) ◽  
pp. 036525 ◽  
Author(s):  
Mohamed Ibrahim Abd El Aal ◽  
Mohamed Adel Taha ◽  
A I Selmy ◽  
A M El-Gohry ◽  
H S Kim
Keyword(s):  
Solid State ◽  
Hot Extrusion ◽  
Aa6061 Alloy

Newest Developments on the Manufacture of Helical Profiles by Hot Extrusion

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Material Flow ◽  
Twist Angle ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Die Design ◽  
3D Fem ◽  
Extrusion Dies ◽  
Application Fields ◽  
Twisting Angle ◽  
Screw Rotors

A new innovative direct extrusion process, helical profile extrusion (HPE) is presented, which increases the flexibility of aluminum profile manufacturing processes. The application fields of such profiles can be seen in screw rotors for compressors and pumps. The investigations concentrate on experimental and numerical analyses by 3D-FEM simulations to analyze the influence of friction and the material flow on the twisting angle and contour accuracy. By means of finite-element method (FEM), the profile shape could be improved by modifying the die design. The numerical results were validated by experiments. For these investigations, a common aluminum alloy AA6060 was used. Mainly, the friction in the die influences the twist angle and the shape of the helical profile. Two die coatings were analyzed, but the friction was not substantially decreased in any of these cases. Although there is no efficient practical solution for reducing the friction in extrusion dies using tested die coatings, the required profile contour could be achieved by new die designing and by modifying the material flow. However, increasing the twist angle is limited due to geometrical aspects of this technology, namely, by the ratio of the volume to the contact area with the die for the displaced metal.

Fracture Analysis and Mechanical Property of AZ91D Magnesium Alloy Chips Prepared by Solid State Recycling

2006 ◽  
Vol 324-325 ◽  
pp. 499-502
Author(s):  
Ze Sheng Ji ◽  
Mao Liang Hu ◽  
Xiao Yu Chen
Keyword(s):  
Mechanical Properties ◽  
Solid State ◽  
Magnesium Alloy ◽  
Hot Extrusion ◽  
Casting Process ◽  
Fracture Analysis ◽  
Extrusion Ratio ◽  
Cold Press ◽  
Az91d Magnesium Alloy ◽  
Chips Recycling

AZ91D magnesium alloy is prepared by hot extrusion of recycled machined chips and its fractures and mechanical properties are investigated at various extrusion conditions. Cold-press is employed to prepare extrusion billets of AZ91D magnesium alloy chips, and then the billets are hot extruded at 573K-723K with an extrusion ratio of 11:1. The results show that tensile strength and elongation of the extrusion magnesium alloy with the extrusion temperature of 673K and the extrusion rate of 0.08mm/s can reach 380MPa and 6%, respectively. Fracture surface presents a mix mechanism of dimple-like fracture and gliding fracture. Due to grain refinement by cold-press and hot extrusion, mechanical properties of extruded rods are much higher than those of as-cast AZ91D magnesium alloy. Also, much lower energy consumption is necessary for this recycling compared to the conventional casting process. Solid state recycling is an efficient method for magnesium alloy chips recycling.

Die design for axisymmetric hot extrusion

1997 ◽  
Vol 37 (11) ◽  
pp. 1635-1650 ◽  
Author(s):  
N. Venkata Reddy ◽  
P.M. Dixit ◽  
G.K. Lal
Keyword(s):  
Hot Extrusion ◽  
Die Design

Newest Developments on the Manufacture of Helical Profiles by Hot Extrusion

2011 ◽  
Author(s):  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Twist Angle ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Die Design ◽  
3D Fem ◽  
Extrusion Die ◽  
Contour Accuracy ◽  
Application Fields ◽  
Twisting Angle ◽  
Screw Rotors

The paper presents a new innovative direct extrusion process, Helical Profile Extrusion (HPE), which increases the flexibility of aluminum profile manufacturing processes. The application fields of such profiles can be seen in screw rotors for compressors and pumps. The investigations concentrate on experimental and numerical analyses by 3D-FEM simulations to analyze the influence of friction on the material flow in the extrusion die in order to find out the optimal parameters with reference to the twisting angle and contour accuracy. By means of FEM, the profile shape could be optimized by modifying the die design. The numerical results were validated by experiments. For these investigations, a common aluminum alloy AA6060 was used. The accuracy of the profile contour could be improved significantly. However, increasing the twist angle is limited due to geometrical aspects.

scholarly journals Effect of Thermally-Treated Chips on Density of AlMgSi Alloys Recycled Using Solid-State Technique

Processes ◽  
2020 ◽  
Vol 8 (11) ◽  
pp. 1406
Author(s):  
Abdullah Wagiman ◽  
Mohammad Sukri Mustapa ◽  
Shazarel Shamsudin ◽  
Mohd Amri Lajis ◽  
Rosli Asmawi ◽  
...  
Keyword(s):  
Solid State ◽  
Treatment Time ◽  
Compaction Pressure ◽  
Hot Extrusion ◽  
Density Variation ◽  
Treatment Temperature ◽  
Extrusion Ratio ◽  
Alumina Layer ◽  
Microstructure Examination ◽  
Thermally Treated

Solid-state recycling is a sustainable technique for recycling aluminium scrap, and the process before recycling is essential to control the physical properties of the product. In this work, the effect of the thermally-treated chips on the extrudate density was investigated. The aluminium chips were thermally-treated to enrich the alumina layer and reduce compaction pressure during chips compaction before recycled using direct hot extrusion. The chips that were transformed into compacted billets were extruded directly without melting and conducted according to 24 full factorial experimental design. The density test on the recycle extrudate found that the density variation ranged from 2724 to 2983 kg/m3. The ANOVA result showed that all factors investigated were statistically significant. The most significant factor was the preheating temperature, followed by extrusion ratio, chip treatment temperature, chip treatment time, and the interaction of chip treatment-time–extrusion ratio. The predictive model suggested by the ANOVA is useful to predict the density with 1% error. Microstructure examination revealed the presence of alumina entrapped in the recycle extrudate, in which thermal-treated chips contained more alumina than that of the untreated chips. The result indicated that the thermal treatment performed on the chips had enriched the in-situ alumina, affecting the density of the recycle extrudate.

FEM Simulation of the Whole Circle of Aluminum Hot Extrusion Using Circular Dies With Different Extrusion Angle

2006 ◽  
Author(s):  
A. Lontos ◽  
K.-D. Bouzakis ◽  
G. Demosthenous ◽  
A. Baldoukas
Keyword(s):  
Product Quality ◽  
Process Parameters ◽  
Surface Condition ◽  
Fem Simulation ◽  
Hot Extrusion ◽  
Die Design ◽  
Work Piece ◽  
Billet Temperature ◽  
Extrusion Die ◽  
Ram Speed

On of the most typical forming processes used for the production of long, straight semi-finished products in the form of various section geometries is extrusion. Hot extrusion is a thermo-mechanical process whish involves complicated interactions between process parameters, tooling and deforming material /1,2/. In the present paper, FEM simulation is performed in the aluminum extrusion using circular dies with different geometries in order to extract quantitative simulating results regarding various forming parameters. Most specifically the parameters that are investigated are the die design-geometry, the process parameters (i.e. ram speed, container temperature, billet temperature) and the product quality (i.e. extruded shape, surface condition). The finite element modeling is based on 3D simulation tools using the DEFORM 3D software /3–5/. The used work piece is the aluminum AA6061 in cylindrical form with a diameter of 14 mm. The used material for the extrusion die is the hot work steel AISI H13. The geometry of the die is circular with a variation in die angle. The container and the billet temperature will vary from 450 to 550 degrees, and the mandrel (ram) speed will be at the range of 2 mm/sec. On the basis of simulating results such as pressure distribution on the extrusion die, effective stresses on the billet and product quality, new and improve die geometry will be introduced. Although the simulation problem is an axisymmetric one the authors decide to proceed with 3D FEM simulation in order to examine and verify the 3D simulating results. This paper is the first part of a further research project in which more complicated die geometries will be used as simulating and experimental specimens. In addition to simulating results, experimental results will be presented in the next few months.

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