The origin of weld seam defects related to metal flow in the hot extrusion of aluminium alloys EN AW-6060 and EN AW-6082

Bakker, A.; Werkhoven, R.J.; Sillekens, W.H.; Katgerman, L.

doi:10.1016/j.jmatprotec.2014.05.001

Cited by 40 publications

(3 citation statements)

References 7 publications

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“…The bonding strength at the welding seams affected by the porthole die design dominates the whole material properties of the extrudate. Bakker et al [15] investigated the occurrence of defects inside the extrudate in a direct hot extrusion process of AW-6060 and AW-6082 aluminum alloy billets with an obstacle at the center of the die. The effects of different geometries of the weld-chamber and the processing conditions on the quality of the welding seams were discussed.…”

Section: Introductionmentioning

confidence: 99%

Die Design and Finite Element Analysis of Welding Seams during Aluminum Alloy Tube Extrusion

Hwang

Hsu

2023

Metals

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Hollow tubes are generally manufactured using porthole die extrusion. A finite element software QForm is used to analyze the material flow of aluminum alloy A6061 tubes inside a specially designed porthole die during tube extrusion. High welding pressure and shorter transverse seam length are required for a sound product. Various extrusion conditions and die geometries and dimensions affect the bonding strength of the products. In this paper, the effects of die geometries on the welding pressure are discussed using the Taguchi method. The simulation results show that a higher welding pressure is obtained with a larger porthole radius, a larger welding chamber height, and a larger bearing length, while a larger bridge width increases the welding pressure slightly. For transverse seam lengths, a shorter transverse seam length can be obtained with a smaller porthole radius and a smaller welding chamber height, and a shorter bridge width and bearing length decrease the transverse seam length slightly. The transverse seam region and flow patterns are observed. Tube expanding tests were also conducted. From the expanding test results, it is known that the fracture position did not occur at the welding line and the bonding strength could reach up to 160 MPa.

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Section: Introductionmentioning

confidence: 99%

Die Design and Finite Element Analysis of Welding Seams during Aluminum Alloy Tube Extrusion

Hwang

Hsu

2023

Metals

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“…They indicated that a better welding performance and improved tooling residual stress could be obtained. Den Bakker et al studied the effects of various geometries of the weld chamber on the quality of the longitudinal and transverse weld seams and pointed out that the corresponding mechanical properties were greatly affected by the density of the oxide particle population [14,15]. Zhang et al d the effects of the extrusion die's structure on the length of the transverse weld of an AA7N01 hollow profile [16].…”

Section: Introductionmentioning

confidence: 99%

Assessment of Metal Flow Balance in Multi-Output Porthole Hot Extrusion of AA6060 Thin-Walled Profile

Xue

Vincze

Péreira

et al. 2018

Metals

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For the porthole hot extrusion of a thin-walled tube based on metal flow, the role of the die's structure should be focused on to achieve precision formation, especially for multi-output extrusion and/or complex cross-sectional profiles. In order to obtain a better metal flow balance, a multi-output porthole extrusion die was developed, including some novel features such as a circular pattern of the portholes with a dart-shaped inlet bridge, a buckle angle in the inlet side of the upper die, a two-step welding chamber, and a non-uniform bearing length distribution. Through the use of thermo-mechanical modeling combined with the Taguchi method, the underlying effects of key die features were investigated, such as the billet buckle angle, the porthole bevel angle, the depth of the welding chamber, and the type of bridge on the metal flow balance. The experimental validation showed that the developed numerical model for the multi-output porthole extrusion process had high prediction accuracy, and was acceptable for use in an industrial extrusion with a complex section.

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“…[129]. Furthermore, Den Bakkera et al [130] show that in the solid-state bonding, the degree of atomic bonding on the coalesced interfaces of weld seams on fracture surfaces determines the size and depth of the emerged dimples which also responsible for the ductility of the extruded profiles.…”

Section: Comparison Between Predicted and Actual Strengthmentioning

confidence: 99%

An analysis of solid-state recycling of aluminium alloy AA6061 from controllable hot extrusion processes

Shamsudin¹

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Solid-state recycling of machining chip wastes via hot extrusion has nowadays been seen important to reduce energy consumption and greenhouse effect, perceived more important than the recycling by remelting. Characteristics of machining chips that are micro in size and large area-to-volume ratio in nature, melting can cause a massive molten metal vaporization leading to huge material losses. The hot extrusion process Contents iv

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The origin of weld seam defects related to metal flow in the hot extrusion of aluminium alloys EN AW-6060 and EN AW-6082

Cited by 40 publications

References 7 publications

Die Design and Finite Element Analysis of Welding Seams during Aluminum Alloy Tube Extrusion

Die Design and Finite Element Analysis of Welding Seams during Aluminum Alloy Tube Extrusion

Assessment of Metal Flow Balance in Multi-Output Porthole Hot Extrusion of AA6060 Thin-Walled Profile

An analysis of solid-state recycling of aluminium alloy AA6061 from controllable hot extrusion processes

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