Numerical Simulation of Superalloy IN718 during Tube Hot Extrusion

2009 ◽  
Vol 83-86 ◽  
pp. 157-164 ◽  
Author(s):  
Chao Yang Sun ◽  
Qing Dong Zhang
Keyword(s):  
Temperature Rise ◽  
Great Influence ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Extrusion Force ◽  
Technological Parameters ◽  
Jet Engine ◽  
Technological Factors ◽  
Preheating Temperature ◽  
Ram Speed

Superalloy IN718 large tube is used in critical jet engine applications, while manufacturing such components, the control of temperature during tube hot extrusion is of paramount importance. To determine the relation between technological factors and the temperature rise, extrusion force during tube hot extrusion of superalloy IN718, a numerical model was developed to for the large tube hot extrusion through die and over mandrel. The constitutive behaviour of the material and friction at the extrusion temperatures are established as a thermoplastic process. In order to investigate the influence of technological parameters of extrusion process on the temperatures rise and extrusion force, then the extrusion variables such as friction factor, ram speed, tool and billet preheating temperature are taking into consideration. Besides tool preheating temperature, other parameters have a great influence on temperature rise of billet during the extrusion process. All of technological parameter of study in this paper have a significant influence on the extrusion force. Moreover, based on the simulation results, the case with tool preheating temperature of 300°C should avoid during the technology making.

Study on Extrusion Forming of Superalloy Tube under Different Dies

2010 ◽  
Vol 145 ◽  
pp. 380-385
Author(s):  
Yi Lun Mao ◽  
Qing Dong Zhang ◽  
Chao Yang Sun
Keyword(s):  
Temperature Rise ◽  
Metal Flow ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Steel Tube ◽  
Flow Rule ◽  
Extrusion Force ◽  
Tube Extrusion ◽  
Extrusion Die ◽  
Inconel 690

Extrusion die is a key factor in tube extrusion deformation. This paper, studying Inconel 690 alloy steel tube hot extrusion process by adopting Deform-2D software, analyses the influence of flat dies, cone die and flat-cone die on extrusion force, temperature rise, and metal flow rule during superalloy extrusion process and find that cone die is more helpful for superalloy tube extrusion. Based on it, the influence rule of cone die angle on extrusion force and temperature rise is studied, and the best die angle for superalloy tube extrusion is provided, which offer the evidence for the design of superalloy tube extrusion die

Effect of Hot Extrusion Parameters on Tensile Strength and Fracture Behavior in Direct Recycling of Aluminium Alloy (6061) Chips

2020 ◽  
Vol 975 ◽  
pp. 229-234
Author(s):  
Mohammed H. Rady ◽  
Mohammad Sukri Mustapa ◽  
Shazarel Shamsudin ◽  
Mohd Amri Lajis ◽  
Mohd Idrus Mohd Masirin ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Optimum Condition ◽  
Fracture Behavior ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
High Tensile Strength ◽  
Preheating Temperature ◽  
Aluminum Chips ◽  
Full Factorial ◽  
Alloy 6061

Produced Profiles by direct recycling of aluminum chips in hot extrusion process were achieved by temperature related parameters using preheating temperature 450 °C, 500 °C, and 550 °C for duration 1 hour, 2 hours, and 3 hours preheating time. By using Design of Experiments (DOE) procedure with full factorial design and three center points analysis, the results showed that the preheating temperature factor is more important to be controlled rather than the preheating duration and increase of temperature conducted to the high tensile strength. The profiles extruded at 550 °C and 3 hours’ duration had obtained the optimum condition to get the maximum tensile strength. The influence of parameters of hot extrusion process on fracture surfaces of the recycled samples was also investigated and discussed.

scholarly journals Effect of Process Parameters and Definition of Favorable Conditions in Multi-Material Extrusion of Bimetallic AZ31B–Ti6Al4V Billets

2020 ◽  
Vol 10 (22) ◽  
pp. 8048
Author(s):  
Daniel Fernández ◽  
Alvaro Rodríguez-Prieto ◽  
Ana María Camacho
Keyword(s):  
Influencing Factor ◽  
Element Model ◽  
Extrusion Process ◽  
Extrusion Force ◽  
Core Diameter ◽  
The Core ◽  
Ram Speed ◽  
Definition Of ◽  
Favorable Conditions ◽  
Influential Parameters

This paper investigates the extrusion process to manufacture bimetallic cylinders combining a magnesium alloy core (AZ31B) and a titanium alloy sleeve (Ti6Al4V) of interest in aeronautical applications. A robust finite element model has been developed to determine the most influential parameters and to study the effect of them on the extrusion force and damage induced by means of Design of Experiments (DOE) and Taguchi method. The results show that the most influential parameters in the extrusion forces are the friction between sleeve and container/die and the height of the cylinder; and the less influential ones are the process temperature and ram speed. Moreover, minimum values of forces along with low damage can be reached by favorable interface contact conditions, minimizing the friction at the core-container/die interface, as the main influencing factor; followed by the geometrical dimensions of the billet, being the billet height more important when paying attention to the minimum forces, and being the core diameter when considering the minimum damage as the most important criterion. The results can potentially be used to improve the efficiency of this kind of extrusion process and the quality of the extruded part that, along with the use of lightweight materials, can contribute to sustainable production approaches.

Simulation of the Grain Structure Evolution of a Mg-Al-Ca-Based Alloy during Hot Extrusion Using the Cellular Automation Method

2011 ◽  
Vol 491 ◽  
pp. 265-272 ◽  
Author(s):  
L. Li ◽  
F. He ◽  
X. Liu ◽  
Yan Lou ◽  
Jie Zhou ◽  
...  
Keyword(s):  
Hot Extrusion ◽  
Extrusion Process ◽  
Grain Structure ◽  
Structure Evolution ◽  
Compression Tests ◽  
3D Fem ◽  
Parameter Recovery ◽  
Cellular Automation ◽  
Average Grain Size ◽  
Ram Speed

In the present study, the evolution of the grain structure of a Mg-Al-Ca-based alloy during hot extrusion was simulated with the cellular automation method. The Laasraoui-Jonas microstructure model was used to describe the dislocation evolution inside crystallites during dynamic recrystallization. The parameters in the Laasraoui-Jonas model, such as the hardening parameter, recovery parameter and material constants, were determined from the flow stress-strain data obtained from hot compression tests using a Gleeble-1500 thermomechanical simulator. The extrusion process was simulated using a DEFORM 3D FEM code. The influence of ram speed on grain structure evolution was analyzed. It was found that the average grain size increases with increasing ram speed. Good agreements between the predicted and observed grain structures were achieved.

Research on Thixoforging Magazine Plate of AZ91D Magnesium Alloy in Semi-Solid State

2006 ◽  
Vol 116-117 ◽  
pp. 267-270 ◽  
Author(s):  
Ju Fu Jiang ◽  
Shou Jing Luo
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Solid State ◽  
Magnesium Alloy ◽  
Room Temperature ◽  
Great Influence ◽  
Technological Parameters ◽  
Az91d Magnesium Alloy ◽  
Preheating Temperature ◽  
Semi Solid

The thixoforging process in which magazine plates of AZ91D magnesium alloy were thixoforged in semi-solid state using semi-solid billets prepared by common SIMA method and new SIMA method was investigated. The results show that the pressure has a great influence on the semi-solid billet’s ability to fill die’s cavity. When the pressure is 500KN, the semi-solid billet can’t fill the die’s cavity completely. When the pressure is 2000KN, the semi-solid billet can fill the die’s cavity completely. Room temperature mechanical properties, such as yield strength of 201.4MPa, ultimate tensile strength of 321.8MPa and elongation of 15.3%, can be obtained successfully when the technological parameters, including pressure of 200KN, die preheating temperature of 723K, holding for 20min at 818K, are satisfied. Comparing with common SIMA, mechanical properties of room temperature and high temperature at 373Kare enhanced heavily.

Analyses of Plastic Flow and Die Design during Hot Extrusion of Magnesium Alloy Strips

2010 ◽  
Vol 443 ◽  
pp. 98-103 ◽  
Author(s):  
Yeong-Maw Hwang ◽  
Shih Ming Tu
Keyword(s):  
Magnesium Alloy ◽  
Plastic Flow ◽  
Thickness Distribution ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Die Design ◽  
Thin Strip ◽  
Compression Tests ◽  
Ram Speed ◽  
Product Thickness

This study involves analyses and experiments of hot extrusion of magnesium alloy strips. Hot compression tests were firstly conducted to obtain the magnesium alloy’s plastic flow stresses at high temperatures. These data are used in the finite element simulations of the thin strip extrusion process. Using the FE simulations, the flow pattern of the magnesium alloy billet within the die, the temperature variation and the thickness distribution at the die exit were analyzed. The effects of different die bearing height design, initial billet temperatures and ram speed on the extrusion load, the temperature at the die exit and the product thickness distribution were also discussed. Finally, hot extrusion experiments were conducted and the experimental values of the extrusion load and dimensions of the products were compared with the analytical values to validate the analytical model. Sound products were obtained using the best designed bearing heights and other appropriate extrusion conditions.

Rheo-Extrusion of Hypereutectic Al-14.8Si-4.5Cu-1.1Mg Alloy

2011 ◽  
Vol 409 ◽  
pp. 57-62
Author(s):  
Nanako Mori ◽  
Yasuhiro Uetani ◽  
Masayoshi Dohi ◽  
Kenji Matsuda ◽  
Susumu Ikeno
Keyword(s):  
Hot Extrusion ◽  
Extrusion Process ◽  
Extrusion Ratio ◽  
Age Hardening ◽  
Peak Hardness ◽  
Extrusion Force ◽  
Gravity Casting ◽  
Primary Si ◽  
Semi Solid ◽  
Hardness Values

Rheo-extrusion of hypereutectic Al-14.8%Si-4.5%Cu-1.1%Mg (in mass%) alloy which is considerably difficult to hot-extrude was tried using semi-solid slurry with fine solid granules and almost finely dispersed primary Si particles, made by a newly developed rotor process. Trials of rheo-extrusion at the constant extrusion ratio of 36 using this semi-solid slurry were carried out at the different conditions of the extrusion temperature and the ram speeds ranging from 520 to 560oC and from 5 to 20mm/s, respectively. Under the all rheo-extrusion conditions, this semi-solid slurry could easily be rheo-extruded to the round bars of 6mm diameter with sound surface at much lower extrusion force than that of hot-extrusion at very low extrusion ratio. In addition, the characteristic age-hardening behavior which is thought to be essential for the rheo-extrusion process has been found out, namely the peak hardness values of aged bars rheo-extruded at 520 and 540oC were considerably higher, 30HV at maximum, than that of a gravity casting.

scholarly journals MULTIPLE PROCESS PARAMETER OPTIMIZATION OF FORWARD EXTRUSION PROCESS ON AA 2024

2021 ◽  
Vol 13 (2) ◽  
pp. 63-75
Author(s):  
Anupama Francy Kothasiri ◽  
◽  
Srinivasa Rao Chalamalasetti ◽  
Gopalakrishnaiah Peteti ◽  
◽  
...  
Keyword(s):  
Coefficient Of Friction ◽  
Parameter Optimization ◽  
Process Parameters ◽  
Extrusion Process ◽  
Work Piece ◽  
Extrusion Force ◽  
Input Process ◽  
Level 3 ◽  
Level 1 ◽  
Ram Speed

Extrusion is a simple metal forming process in which a block of metal is forced through a die orifice with a certain shape under high pressure. This extrusion process is influenced by many process parameters such as die angle (DA), ram speed (RS), coefficient of friction (COF), Extrusion ratio, Die land height, work piece diameter and length, material properties etc. In extrusion process, extrusion force is crucial parameter, the flow of metal and hence the extrusion force is significantly influenced by the above parameters which results in quality of the product. The present study numerically investigates the influence of major process parameters such as die angle, ram speed, coefficient of friction on the extrusion process. The AA2024 material is chosen as work piece material and the extrusion force and damage is considered as the output responses. The input process parameters are varied in three levels (Level - 1: 10° DA, 1.6mm/min RS, 0.06 COF; Level - 2: 20° DA, 3.2mm/min RS, 0.08 COF; Level - 3: 30° DA, 4.8mm/min RS, 0.01 COF). Numerical simulations are performed by using DEFORM 3D software. The simulations are conducted as per L27 orthogonal array. From the results it is observed that Increase of die angle, ram speed and coefficient of friction increases the extrusion force. The die angle has highest (86.45%) influence on the extrusion force, then after ram speed (6.60%). The coefficient of friction has insignificant influence (0.55%). It is also noticed that the damage is considerable after the 20° die angle. A multi parameter optimization is also done by using the Grey relation analysis by considering the equal weightage of extrusion force and damage. The optimum levels of input process parameters for the minimum extrusion force and damage is DA level 1, RS level 1, and COF level 3.

Recycling of EN AW 2011 Aluminum Chips without Remelting

2019 ◽  
Author(s):  
Branimir Lela ◽  
Jure Krolo
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Aluminum Alloy ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Extrusion Temperature ◽  
Influential Factor ◽  
Depth Of Cut ◽  
Extrusion Force ◽  
Main Research

This article deals with the direct recycling of EN AW 2011 aluminum alloy chips, which are formed by turning, into semifinished products using forward hot extrusion process. Direct recycling without re-melting is usually called solid-state recycling. The main aim of this article is to investigate the influence of depth of cut (size of chips) in the aluminum alloy turning process, extrusion temperature, and compaction force on mechanical properties, surface roughness, and extrusion force of recycled samples. An original approach to solve this problem is mathematical modelling of the process using the design of experiments. The influence of main research factors on yield strength (Rp0,2), hardness (HV), extrusion force (F), and surface roughness (Ra) of recycled samples has been studied. The study has shown that the most influential factor on mechanical properties, surface roughness, and extrusion force was extrusion temperature.

Effect of Heat Treatment on Tensile Strength of Direct Recycled Aluminium Alloy (AA6061)

2019 ◽  
Vol 961 ◽  
pp. 80-87
Author(s):  
Mohammad Hussein Rady ◽  
Ahmed Sahib Mahdi ◽  
Mohammad Sukri Mustapa ◽  
Shazarel Shamsudin ◽  
Mohd Amri Lajis ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Tensile Strength ◽  
Solid State ◽  
Aging Process ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
High Tensile Strength ◽  
Quenching Temperature ◽  
Preheating Temperature ◽  
Aluminum Chips

Products by solid-state recycling of aluminum chips in hot extrusion process were controlled by temperature related parameters using preheating temperature 450 °C, 500 °C, and 550 °C for 1 hr, 2 hr, and 3 hr preheating time. By using Design of Experiments (DOE), the results found that the preheating temperature is more important to be controlled rather than the preheating time and increasing of temperature led to the high tensile strength. The profile extruded at 550 °C with 3 hr duration had gained the optimum case to get the maximum tensile strength. For the optimum case, heat treatment was carried out using quenching temperature at 530 oC for 2 h and aging process at 175 oC for 4 h. The tensile strength of extrudes specimen was improved significantly compared to those of non-treated specimen.

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