State-of-the-art of extrusion welding and proposal of a method to evaluate quantitatively welding quality during three-dimensional extrusion process

Lü, Xiaoling; Zhao, Guang‐Hui; Guan, Yanjin; Liang, Chen; Gao, Anjiang

doi:10.1016/j.matdes.2015.10.033

Cited by 24 publications

(7 citation statements)

References 58 publications

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“…According to Equation (1), the K values at different ram speeds were calculated. According to the study of Lu et al [ 15 ], three-dimensional values of K can be transformed into nondimensional ones ( K *) by dividing the area of the welding plane. Figure 6 shows the nondimensional K * values.…”

Section: Resultsmentioning

confidence: 99%

Microstructure and Its Influence on the Welding Quality of 6063 Aluminum Alloy Porthole Die Extrusion

Liu

et al. 2021

Materials

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Extrusion experiments and 3D numerical modeling were conducted to investigate the dynamic recrystallization and welding quality of a 6063 aluminum alloy hollow square tube extruded by a porthole die at the ram speeds of 3 mm/s, 7 mm/s, 9 mm/s and 11 mm/s. The results showed that average grain size of hollow square tube extruded at the ram speed of 7 mm/s was the smallest. The profile extruded at the ram speed of 3 mm/s exhibited the highest expansion ratio. Dynamic recrystallization (DRX) fractions were highly variable at different ram speeds. DRX fractions in the matrix zones were higher than those in the welding zones, resulting in smaller grain sizes in the matrix zones. Mechanical properties in the welding zones and matrix zones was different. A local strain concentration would occurred during expansion, which would affect the welding quality. Finally, it was found that the uniform microstructure near the welding line would also affect the welding quality.

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Section: Resultsmentioning

confidence: 99%

Microstructure and Its Influence on the Welding Quality of 6063 Aluminum Alloy Porthole Die Extrusion

Liu

et al. 2021

Materials

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“…Based on the understanding of metal flow from numerical simulation, an extrusion-welding limit diagram was established to predict weld seam quality (Khan et al, 2012). Lu et al (2016) performed numerical simulation and developed a welding criterion. The parameters used in the welding criterion, such as hydrostatic pressure, equivalent stress and strain rate were drawn from numerically simulated results.…”

Section: A C C E P T E D Mmentioning

confidence: 99%

Integrated physical and numerical simulations of weld seam formation during extrusion of magnesium alloy

Bai

Fang

Zhou

2019

Journal of Materials Processing Technology

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Solid-state bonding takes place during the extrusion process to produce a hollow metal profile through a porthole die, known as extrusion welding. Defective weld seams degrade extruded products in mechanical properties. The present research was aimed to determine the effect of extrusion condition on the longitudinal weld seam quality of a magnesium alloy, Mg-8Al-0.5Zn-0.5RE, using an integrated physical and numerical simulation method. A special die set-up for physical simulation was designed, through which two magnesium alloy rods were welded in the solid-state under high hydrostatic pressure. Extrusion welding experiments under different conditions were performed. It was demonstrated that, with this die set-up, the formation of weld seams during extrusion to produce hollow profiles could be physically simulated. The extrusion welding experiments were then numerically simulated to reveal strains, stresses and hydrostatic pressures that could not be experimentally measured. Finally, the tensile strength and elongation of the extrusion-welded magnesium alloy were determined and its microstructure was examined. The results showed that the bonding strength increased with decreasing extrusion speed and rising extrusion temperature. For well-bonded rods, weld seam was invisible under optical microscope. Attributed to high temperature and large equivalent strain, complete dynamic recrystallization occurred across the interface, leading to a reduced average grain size and disappearance of weld seam. By applying the integrated physical and numerical simulation method, extrusion process parameters for a particular magnesium alloy can be optimized to ensure weld seam quality of extruded hollow profiles.

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“…The aluminum hollow extrusions have been extensively used in high-speed train manufacturing industry due to their high rigidity, favorable strength/weigh ratio, good flatness, and excellent corrosion resistance [1]. They can replace the functions of conventional welding components including beams and plates, and thus can simplify the welding procedures and reduce the vehicle's weight [2].…”

Section: Introductionmentioning

confidence: 99%

Relationship Between Microstructures and Microhardness in High-Speed Friction Stir Welding of AA6005A-T6 Aluminum Hollow Extrusions

Liu¹,

Liu

Yu³

2019

Acta Metall. Sin. (Engl. Lett.)

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AA6005A-T6 aluminum hollow extrusions were friction stir welded at a fixed high welding speed of 2000 mm/min and various rotation speeds. The results showed that the heat-affected zone (HAZ) retained the similar grain structure as the base material except some grain coarsening, and the density of dislocations and β′ precipitates were almost unchanged, indicating that the high welding speed inhibited the coarsening and dissolution of β″ precipitates via fast cooling rate. The thermo-mechanically affected zone (TMAZ) was characterized by elongated and rotated grains, in which a low density of β′ precipitates and the highest density of dislocations were observed. The highest heat input and severest plastic deformation occurring in the nugget zone (NZ) resulted in the occurrence of dynamic recrystallization and a high density of dislocations. Hence, all the β″ precipitates and most of the β′ precipitates dissolved into the matrix, and a few β′ precipitates were transformed into β precipitates. The microhardness was controlled by the precipitation and solution strengthening in the HAZ, by the dislocation and precipitation strengthening in the TMAZ, and by the fine-grain and dislocation strengthening in the NZ. With the increase in rotation speed, the peak and the lowest microhardness value increased monotonously.

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State-of-the-art of extrusion welding and proposal of a method to evaluate quantitatively welding quality during three-dimensional extrusion process

Cited by 24 publications

References 58 publications

Microstructure and Its Influence on the Welding Quality of 6063 Aluminum Alloy Porthole Die Extrusion

Microstructure and Its Influence on the Welding Quality of 6063 Aluminum Alloy Porthole Die Extrusion

Integrated physical and numerical simulations of weld seam formation during extrusion of magnesium alloy

Relationship Between Microstructures and Microhardness in High-Speed Friction Stir Welding of AA6005A-T6 Aluminum Hollow Extrusions

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