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TALAT Lecture 1302



               Aluminium Extrusion:
            Alloys, Shapes and Properties
                                 16 pages, 23 figures

                                     Basic Level

        prepared by Roy Woodward, Aluminium Federation, Birmingham




Objectives:
− to provide sufficient information on the extrusion of aluminum and the performance
  of extruded products to ensure that students, users and potential users of those
  products can understand the fabrication features that affect properties and
  ecomomics.
− to show how in consequence alloy choice for any end application depends not only
  on the characteristics required for that end use but also on production requirements.



Prerequisites:
− General knowledge in materials engineering
− Some knowledge about aluminium alloy constitution and heat treatment



Date of Issue: 1994
 EAA - European Aluminium Association



TALAT1302
1302                         Aluminium Extrusion: Alloys, Shapes and
                             Properties

Table of contents

1302 Aluminium Extrusion: Alloys, Shapes and Properties...................................2
  1302.00 Introduction...................................................................................................2
  1302.01 The Extrusion Process ...................................................................................4
  1302.02 The 6000 Series Alloys ................................................................................11
  1302.03 Literature......................................................................................................15
  1302.04 List of Figures ..............................................................................................16


1302.00 Introduction

The term extrusion is usually applied to both the process, and the product obtained,
when a hot cylindrical billet of aluminium is pushed through a shaped die (forward or
direct extrusion, see Figure 1302.00.01). The resulting section can be used in long
lengths or cut into short parts for use in structures, vehicles or components. Also,
extrusions are used for the starting stock for drawn rod, cold extruded and forged
products (Figure 1302.00.02). While the majority of the many hundreds of extrusion
presses used throughout the world are covered by the simple description given above it
should be noted that some presses accommodate rectangular shaped billets for the
purpose of producing extrusions with wide section sizes (Figure 1302.00.03). Other
presses are designed to push the die into the billet. This latter modification is usually
termed "indirect" extrusion (Figure 1302.00.04).

                                                                     DIE




                                          EXTRUSION
                                                                 BILLET                      RAM




                                                    alu
                                                               Forward or Direct Extrusion       1302.00.01
              Training in Aluminium Application Technologies




TALAT 1302                                                            2
The versatility of the process in terms of both alloys available and shapes possible
makes it one of the most valued assets in helping the aluminium producer supply users
with solutions to their design requirements.

                        MAIN PROCESS                           PRODUCT GROUPS                 GENERIC ALLOYS


                                                               SYSTEM OF PROFILES

                                                               STRUCTURAL SECTIONS                 AlMgSi
                                                                                                   (AA6060)
                                                               FORMED SECTIONS
                         HOT EXTRUSION OF
                                     PROFILES                  MACHINED PARTS                      AlSi1MgMn
                                     TUBES                        CUT                              (AA6082)
                                                                  BLANKED
                                    ROD
                                                                  MILLED
                                                                                                   AlMn1
                                                               COLD DRAWN SECTIONS
                                                                                                   (AA3103)
                                                                                                   AlSi1Mg
                                                               IMPACT AND COLD EXTRUDED
                                                                                                   (AA6351)
                                                                                                   AlZn5.5MgCu
                                                               FORGINGS
                                                                                                   (AA7075)




                                                      alu
                                                                      Extrusions                        1302.00.02
              Training in Aluminium Application Technologies




                                                     alu

            Training in Aluminium Application Technologies
                                                                  Rectangular Billet                     1302.00.03




                                                                DIE                    SEALING PLATE




                                                               RAM
             EXTRUSION                                                                    BILLET




                                                    alu
                                                                  Indirect Extrusion                     1302.00.04
            Training in Aluminium Application Technologies




TALAT 1302                                                            3
1302.01 The Extrusion Process

The fundamental features of the process are as follows: A heated billet cut from DC cast
log (or for small diameters from larger extruded bar) is located in a heated container, the
actual temperatures of both varying according to alloy and other operation conditions
discussed later, but usually around 450 °C - 500 °C. At these temperatures the flow
stress of the aluminium alloys is very low and by applying pressure by means of a ram to
one end of the billet the metal flows through the steel die, located at the other end of the
container to produce a section, the cross sectional shape of which is defined by the
shape of the die (Figure 1302.01.01). The maximum length of the section depends on
the volume of the billet (cross-section x length) and on the extrusion ratio, i.e. the ratio
of cross-section of the billet to the cross-section of the extrusion. When it is necessary to
obtain very long length of section, as for instance in electrical conductors, it is possible
to introduce successive billets into the container and produce a continuous product. The
interaction between alloy composition, conditions of billet and container, extrusion ratio
and extrusion speed affects metal flow and the resulting properties and structure of the
section and its surface finish, while the actual die configuration and the condition and
shape of the bearing surfaces over which the hot aluminium flows and the die
temperature also contribute. When we add the way in which the section is cooled and
handled after leaving the die it can be seen that a process described as being like
"squeezing tooth paste from a tube" does have a quite complex set of parameters to
control but at the same time a wide variety of means to produce the characteristics
required from the product. The importance of the process to the aluminium industry and
its customers is well illustrated by the fact that over the past 20 years, at four year
intervals, five international conferences have been held in USA at which some 600
technical papers on the extrusion of aluminium and its alloys have been presented. A
sixth such conference will be held in 1996. Few, if any aspects of the process, the
products, their uses, their recycling and predictions for their future have failed to receive
attention.



                            EXTRUSION
                         PLATTEN                              SUB-BOLSTER

                                                                BOLSTER
                                            PLATTEN
                                            PRESSURE
                                                                      BACKER
                                            RING



                                                                                        DIE

                                                                                   DUMMY BLOCK
                                                                                     STEM
                                                                                    BILLET
                                                                                       DIE RING

                                                                                   CONTAINER LINER


                                                                                        CONTAINER


                                                                               DIE SLIDE




                                                   alu
                                                             Typical Die Tooling Assembly For Forward Extrusion   1302.01.01
            Training in Aluminium Application Technologies




TALAT 1302                                                                     4
The temperature at which the section leaves the die must not be so high as to cause
cracking of the product surface or cause it to develop "pick-up" which could make its
appearance unacceptable. The emerging temperature is affected by many of the factors
mentioned above and its control is, therefore, possible in a number of ways. Since for
economic reasons it is desirable to extrude as fast as possible, thus obtaining maximum
output from the press, much attention has been paid to the design of the bearings and to
various die cooling techniques so that the temperature build up in the extruding metal
caused by metal deformation and friction is kept to a minimum and/or reduced by
cooling the die itself or the emerging product.

All aluminium alloys can be extruded but some are less suitable than others, requiring
higher pressures, allowing only low extrusion speeds and/or having less than acceptable
surface finish and section complexity. The term "extrudability" is used to embrace all of
these issues with pure aluminium at one end of the scale and the strong
aluminium/zinc/magnesium/copper alloys or other (see Figure 1302.01.02). Because of
the mentioned complex interaction of process factors this rating can be seen to be
arbitary!

                                          ALLOY                    RATING                   ALLOY            RATING

                                              EC                      150                    6063             100
                                             1060                     150                    6066              40
                                             1100                     150                    6101             100
                                             1150                     150                    6151              70
                                             2011                      15                    6253              80
                                             2014                      20                    6351              60
                                             2024                      15                    6463             100
                                             3003                     100                    6663             100
                                             5052                      80                    7001               7
                                             5083                      20                    7075              10
                                             5086                      25                    7079              10
                                             5154                      50                    7178               7
                                             5254                      50
                                             5454                      50
                                             5456                      20
                                             6061                      60




                                                      alu
                                                                Relative Extrudability of Aluminium Alloys       1302.01.02
               Training in Aluminium Application Technologies




Depending on the size of the section and the size of the billet it is possible to extrude
more than one section per die, up to say eight, thus greatly increasing the press output.
The exact location of the section shapes around the axis is important to ensure that the
sections all emerge at the same speed in order to facilitate handling. Also, even for
single hole dies the metal flow through the die must be controlled by die bearing design
and section orientation with respect to the die axis so that uniform speed by all parts of
the section is achieved (Figure 1302.01.03); otherwise the section will deflect on
emerging and suffer shape distortion. When the sections of heat treated alloys leave the
die they can, depending on the alloy and section thickness, be quenched either in water
or by air cooling, thus rendering a "solution heat treatment", or be taken from the press
for formal solution heat treatment in a furnace. After either of these operations the
sections receive a stretch of between 1 and 2% to remove residual stress followed by
artificial ageing to stabilize their properties. The temper designations for extrusion
products are numerous and a number of typical ones are shown; the most common are
T4, T5 and T6.



TALAT 1302                                                                    5
BACK                                           BACK
                                                                     TAPER                                          TAPER
                        ORIGINAL                                                              ORIGINAL
                        BEARING                                                               BEARING
                        CHOKE                                                                 PRESENT
                                                                                              BEARING
                                                                                              RELIEF




                        DEGREE OF                                              BACK TAPER                                   BACK TAPER
                        CHOKE                                                  UNDERCUT                                     UNDERCUT
                        NEEDED

                                                                                                                            0.003 RELIEF



                                 CHOKED TO SLOW METAL FLOW                                             RELIEVED TO SPEED METAL FLOW




                                                    alu          Methods for Slowing or Speeding Metal Flow                 1302.01.03
             Training in Aluminium Application Technologies               Through an Extrusion Die



                      THE PLANT                                                 FOR DESPATCH


                                                                                                          PACKING
                                                                                                                          HEAT
                                                                                                                        TREATMENT
                                                                                       SAW

                     BILLET-HEATER
                                                                             COOLING
                     & LOG SHEAR
                                                                 PRESS
                                                                                              PULLER

                                                                                             COOLING TABLE
                                       LOGS

                                                     BILLETS
                                                                                              STRETCHER

                                                                                                                       STACKER

                                                              PRE HEATING
                                                              OF DIES




                                                    alu
                                                                            The Process - An Overview                       1302.01.04
             Training in Aluminium Application Technologies




                                                                                                             CIRCUMSCRIBING
                                                                                                             CIRCLE DIAMETER




                                                   alu

         Training in Aluminium Application Technologies
                                                                                Cylindrical Billet                           1302.01.05




TALAT 1302                                                                         6
A typical extrusion plant layout is shown in Figure 1302.01.04. Press load capacities
range from a few hundred tonnes to as high as 20.000 tonnes although the majority
range between 1.000 and 3.000 tonnes. Billet sizes cover the range from 50 mm
diameter to 500 mm with length usually about 2-4 times the diameter and while most
presses have cylindrical containers a few have rectangular ones for the production of
wide shallow sections. Obviously the overall dimensions of a section are related to the
billet diameter (Figure 1302.01.05), and the minimum section thickness relates to the
location of the section within this "circumscribing circle", the complexity of the section
and the alloy see Figure 1302.01.06, Figure 1302.01.07, and Figure 1302.01.08). The
minimum thickness possibly is about 0.5 mm. With these limitations taken into account
it is no exaggeration to say that a designer can have any shape he requires, a claim
supported by the fact that some extruders have over 100,000 dies at their disposal. In
designing a section to meet his requirements a user is well advised to consult at an
earlier stage with the suppliers. Both solid and hollow sections can be supplied by any
extrusion plant, but there are differences in the philosophy of design and manufacture of
the dies for the latter which affect both cost and quality of the product; also some
structural features of the product may require modification for better extrudability.

                            METAL THICKNESS mm
                            5.00
                                                                                                                  HOLLOWS & SEMI HOLLOWS

                                                                                                                  DEEP CHANNELS
                              4.00
                                                                                                                  MEDIUM DEEP CHANNELS,
                                                                                                                  ANGLES & FLATS.
                              3.00



                              2.00



                              1.00

                                                                                                                    CIRCUMSCRIBING
                                                                50       100         150   200      250     300     CIRCLE DIAMETER mm



                                                       alu           A Guide to Minimum Section Thickness for
                                                                                                                             1302.01.06
              Training in Aluminium Application Technologies                     6063 Extrusions



                              SECTION TYPE                                 CCD mm           THICKNESS mm             SHAPE FACTOR
                                                                               142                  2.5                     300
                                                                                70                  1.5                     500
                                                                               112                  5.0                     152
                                                                               142               SOLID                       15
                                                                               70                SOLID                       30
                                                                               50                   3.0                     247
                                                                               50                   1.5                     494

                                                                               210                  3.0                     190
                                                                               210                  2.0                     285

                                                                               140               2.0/6.0                    183

                                                                               40                2.0/1.5                    430




                                                                                                           PERIPHERY
                                                      alu
                                                               Shape Factor Values SHAPE FACTOR =      CROSS SECTION AREA
                                                                                                                             1302.01.07
              Training in Aluminium Application Technologies




TALAT 1302                                                                            7
STRENGTH (MPa)
                             Rp 0.2
                                                              AlZn6MgCu (7000 series)
                             Rm           500                                                                                        MIN. WALL
                                                                                                                                    THICKNESS
                                                                                                                                        (mm)
                                          400                                                                                       10
                                                                                                                                     9
                                                                                AlSi1MgMn (6082)                                     8
                                          300
                                                                                                                                     7
                                                                                                                                     6
                                          200                                                                                        5
                                                                                                         AlMgSi (6060)               4
                                                                                                                                     3
                                          100
                                                                                                                    Al 99.5          2
                                                                                                                                     1
                                               0                                                                                     0
                                                       0                  50                 100                  150 EXTRUDABILITY INDEX
                       EXTRUSION
                       SPEED
                                                     0.5 - 2 M/min                       10 - 80 M/min            20 - 100 M/min



                                                    alu
                                                                       Extrudability of Various Alloys                             1302.01.08
             Training in Aluminium Application Technologies




Simple hollow sections such as rounds, squares and ovals can be produced from a
hollow billet using a mandrel (Figure 1302.01.09). Here the product has a uniform
structure across the section. More complex sections are made using bridge or port hole
dies in which the metal flows around a shaped bridge and joins again by hot pressure
welding in a mixing chamber (Figure 1302.01.10). The design of such dies requires a
great deal of experience although the use of C.A.D. and the understanding of metal flow
is helping to add "science" to what is in effect an "art". Because the deformation
experienced by the "welds" is different from that received by other parts of the cross
section a metallurgical examination of the cross section reveals differences in grain
structure at the welds and if the mixing chamber design and extrusion conditions are
less than optimum the weld lines can be obvious on the section surface. When properly
made, however, the difference in structure causes no significant reduction in section
performance, although mechanical tests across the weld do show how some reduction in
both strength and elongation do occur. Hollow sections made from bridge dies are used
in critically stressed applications, the accumulated experience of both producers and
users guaranteeing their integrity when produced under the controlled conditions
obtaining in reliable producers plants.


                           RAM                                                                                           DIE

                                                                                LINER



                                                                                        MANDREL                           TUBING




                                                                                        BILLET




                                                    alu
                                                                  Extruding Tubing with Die and Mandrel                            1302.01.09
             Training in Aluminium Application Technologies




TALAT 1302                                                                        8
WELD AREA

                     PRESSURE
                                                                                                            EXTRUDED TUBE

                                                                                        DIE
                                                                              MANDREL NOSE
                                          SOLID BILLET               BRIDGE




                                                      alu
                                                                       Extrusion of Hollow Section                1302.01.10
              Training in Aluminium Application Technologies




                                                                Steel- and Aluminium Girders
                                                               with the same Bending Stiffness




                                     Steel                     Aluminium           Aluminium         Aluminium
                                                               appro. 50%          increased         increased torsional
                                                               lower weight        torsional         stiffness and
                                                               vs. steel           stiffness         integrated functions


                                                    alu

           Training in Aluminium Application Technologies
                                                                Designing Extrusions with Improved Stiffness       1302.01.11



The ease with which aluminium alloys can be extruded to complex shapes makes valid
the claim that it allows the designer to "put metal exactly where it is needed", a
requirement of particular importance with a relatively expensive material. Furthermore,
this flexibility in design makes it easy, in most cases, to overcome the fact that
aluminium and its alloys have only 1/3 the modulus of elasticity of steel (Figure
1302.01.11). Since stiffness is dependent not only on modulus but also on section
geometry it is possible, by deepening an aluminium beam by around 1,5 times the steel
component it is intended to replace, to match the stiffness of the steel at half the weight.
Also, at little added die cost, features can be introduced into the section shape which
increase torsional stiffness and provide grooves for say fluid removal, service cables,
anti-slip ridges etc. Such features in a steel beam would require joining and machining,
thus adding to the cost and narrowing the gap between initial steel and aluminium costs.
Good examples of this use of the flexibility of extrusions in design are found in the use
by AUDI of over a hundred different extruded shapes in space frame construction
(Figure 1302.01.12). The cost of extrusion dies obviously has to be taken into account

TALAT 1302                                                                     9
in costing the use of extrusions but because the operating temperatures for aluminium
are low compared with the temperatures at which steels can be used, viz around 500 °C,
no special steels are required for dies thus keeping material costs low (Figure
1302.01.13). Obviously, very complex wide hollow dies are much more expensive than
those for small solid sections but the latter cost as little as a few hundred ECU, and
while the former might cost several thousand ECU the advantages to be gained by their
use, particularly when large quantities of section from any one die are required, can
readily counter that cost, as is well demonstrated by the extensive use of large, very
complex sections in rail and road transport (Figure 1302.01.14).



                                                              Audi A8 Aluminium Spaceframe




                                                   alu
                                                                                   Audi A8 Aluminium Spaceframe             1302.01.12
          Training in Aluminium Application Technologies




                                                                           Tool Cost ( US $ )
                                                                    $                                                  $
                                                           1,5
                                                               00                                                  800
            20 mm                                                                                     20 mm




                                                                        130 mm                                     50 mm




                                                                                                                            $
                                                                                                                      00
                                                                                                                  1,5
                                                                                                      50 mm
          100 mm




                                                                                   $
                                                                        00
                                                                    1,5
                                                                                                                    50 mm




                                                                          130 mm

                                                     alu

            Training in Aluminium Application Technologies
                                                                          Example of Tool Costs for Extrusions          1302.01.13




TALAT 1302                                                                             10
1100
                                                                              4                                  570




                                                        1
                                                                        570


                                                                  100               800
                     45                                     5                 45                            85
                                                   270                            260




                                                                                                    500




                                                                                    Dimensions in mm.



                                                  alu
                                                            Hollow Sections Produced Using Rectangular Container       1302.01.14
           Training in Aluminium Application Technologies




1302.02 The 6000 Series Alloys

As indicated in earlier sections all aluminium alloys can be extruded. However, while
large quantities of pure aluminium are extruded for production of electrical conductors,
strong alloys in the 2000, 7000 and 8000 series used for spars and stringers in airframe
construction and large sections in the 5000 series employed in marine structures, the
biggest share of the extrusion market is taken by the 6000, AlMgSi series (see Figure
1302.02.01, Figure 1302.02.02 and Figure 1302.02.03). This group of alloys have an
attractive combination of properties, relevant to both use and production and they have
been subject to a great deal of R & D in many countries, mainly UK, USA, Germany,
France, Switzerland and Japan. The result is a set of materials ranging in strength from
150 Mpa to 350 Mpa, all with good toughness and formability. They can be extruded
with ease and their overall "extrudability" is good but those containing the lower limits
of magnesium and silicon e.g. 6060 and 6063 extrude at very high speeds - up to 100
m/min with good surface finish, anodising capability and maximum complexity of
section shape combined with minimum section thickness. Their strengths are at the
bottom end of the range, and they find wide use in architectural applications where
shape and finish are more important than strength. Also, the elastic modulus of all the
6000 series is the same, as is their fatigue strength when welded and these two facts
coupled with the other attractive features of the 6063/6005A type make them of
increasing value in transport applications. Here stiffness and fatigue often override
strength as a requirement, and the complexity of thin sections possible with the lower
strength versions means that maximum advantage can be taken of the reduction in
welding costs made possible by their use. Rail coach construction reflects this situation
and it is in this application that full advantage has been taken of the aforementioned use
of rectangular containers to allow production of wide sections. The stronger 6082 type
alloys are used for members where tensile strength and impact resistance as well as


TALAT 1302                                                                              11
stiffness and fatigue are important. All of the 6000 series alloys suffer a reduction of
strength at the fusion welds used in construction and this has to be taken into account in
design. There is ample data to show how this is done.

                                                                            %Mg

                                                                                                                       AA 6082
                                                                     1.2

                                                                     1.0
                                                                                       AA 6063
                                                                     0.8

                                                                     0.6

                                                                     0.4                                         AA6005A
                                                                                         AA 6060
                                                                     0.2

                                                                                                                                         %Si
                                                                                   0.2    0.4    0.6   0.8       1.0        1.2




                                                          alu
                                                                             Composition of some AlMgSi Alloys                                         1302.02.01
                  Training in Aluminium Application Technologies




                  ALLOY                                   COMPOSITION % (Remainder Al)
                    BS 1474                                                                                                                      OTHERS
                    (1987)                           Si Fe Cu Mn Mg Cr Ni Zn Ti                                                                 EACH TOTAL
                                                   0.20-                                 0.45-
                       6063                        0.60
                                                         0.35              0.10   0.10
                                                                                         0.90
                                                                                               0.10          -     0.10           0.10          0.05        0.15

                                                   0.30- 0.15-                           0.60-
                      6063A                        0.60 0.35
                                                               0.10               0.15
                                                                                         0.90
                                                                                               0.05          -     0.15           0.10          0.05        0.15

                                                   0.70-                          0.40- 0.60-
                       6082                        1.30
                                                         0.50              0.10
                                                                                  1.00 1.20
                                                                                              0.25           -     0.20           0.10          0.05        0.15

                                                   0.30-                                 0.40-
                      6101A                              0.40              0.05    -               -         -          -          -            0.03        0.15
                                                   0.70                                  0.90
                                                   0.20-                                 0.45-
                       6463                              0.15              0.20   0.05             -         -         0.05        -            0.05        0.15
                                                   0.60                                  0.90
                                                   0.50-                   3.90- 0.40- 0.20-                                      0.15-
                                                         0.50                                0.10       0.40       0.25                         0.05        0.15
                      2014A                        0.90                    5.00 1.20 0.80                                         0.20

                                                                                                                                           Ti + Zr

                                                                    Chemical Composition of Some Aluminium Alloys
                                                         alu

                                                                               Produced as Extrusions                                                  1302.02.02
                 Training in Aluminium Application Technologies




                                                 TEMPER                 MAX.               0.2% PS ULTIMATE                             % ELONGATION
                                                                                           N/mm22 STRENGTH
                     ALLOY                                           THICKNESS                          2                              5.65 So  50 mm
                                                                        mm                          N/mm 2
                                                          F                200                -                  100                       13               12
                                                          T4               150               70                  130                       16               14
                     6063                                 T5                25              110                  150                        8                7
                                                          T6               150              160                  195                        8                7

                                                          T4                25               90                  150                       14               12
                     6063A                                T5                25              160                  200                        8                7
                                                          T6                25              190                  230                        8                7
                                                          F                200                -                  110                       13               12
                     6082                                 T4               150              120                  190                       16               14
                                                          T5                 6              230                  270                        -                8
                                                          T6                20              255                  295                        8                7

                     6101A                                T6                 -              170                  200                       10                8
                                                          T4                50               75                  125                       16                 -
                     6463                                 T6                50              160                  185                       10                 -
                                                          T4                20              230                  370                       11               10
                     2014A                                T6                20              370                  435                        7                6
                                                                                                                                          So = cross-sectional area
                 Source: Aluminium Extrusions - a technical design guide, The Shapemakers, UK, 1991

                                                          alu               Properties of Some Aluminium Alloys                                        1302.02.03
                   Training in Aluminium Application Technologies
                                                                                  Produced as Extrusions



A further advantage of the use of 6063/6005A type alloys lies in their attractive response
to the thermal treatments required to provide their properties. All of the 6000 series


TALAT 1302                                                                                 12
alloys have to be quenched from the "solution heat treatment" temperature in order to
achieve their optimum mechanical properties, the critical temperature range depending
on the actual composition. Also the cooling rate from the S.H.T. temperature is
important. For the 6063 types the range of temperature from which quenching takes
place is wide and for most sections cooling in air provides an adequate rate, particularly
if forced air cooling is employed. While the stronger, 6082 types can be quenched at the
press, i.e. the heat generated in the extrusion process is sufficient to provide S.H.T. the
alloys are quench-sensitive and require water cooling for other than thin sections. The
gentle rates occurring with air cooling have the added advantage of reducing or avoiding
any distortion of the sections (see Figure 1302.02.04).



                      [°C] 700



                                 600



                                 500



                                 400                              AA6060            AA6082
                                                           T6     180 - 220     255 - 330    R p0.2 [Mpa]
                                                           T6     200 - 260     295 - 345    Rm      [Mpa]
                                 300


                                                                                                                   WEIGHT % Mg2Si
                                                0           0.5               1.0            1.5             2.0



                                                 alu
                                                                Phase Diagram for AlMgSi Alloys                         1302.02.04
          Training in Aluminium Application Technologies




Metal flow during the extrusion (in forward extrusion) is such that the surface of the
extruded product does not derive from the billet surface but is created as a result of
shear across a "dead metal zone" (1302.02.05). It is, therefore, not necessary to remove
the billet cast surface prior to extrusion (in the indirect process there is no dead metal
zone and the product surface is created from the billet surface thus requiring that the
billet be scalped). At the beginning of the forward process little work has gone into the
product and, depending on section size, alloy thickness of section, etc. a portion of the
extrusion is cut off as a discard to avoid supplying material with reduced properties.
Also care is taken to avoid any back-end defects at the end of the cycle. These effects
are well understood and the precautions needed to avoid them affecting material
supplied to the user are established.




TALAT 1302                                                                    13
DEAD METAL ZONE
                                                   CONTAINER




                                     RAM                  BILLET                                PRODUCT




                            PRESSURE PAD                                           DIE
                                                                       BACKUP PLATE




                                                alu
                                                               Flow Metal in Direct Extrusion   1302.02.05
        Training in Aluminium Application Technologies




In forward or direct extrusion the ram pressure not only has to deform the metal but also
overcome the friction between the billet and the container. With the indirect process the
billet and container do not move relative to each other and so all of the available press
load is used for deformation. In consequence of these differences indirect extrusion has
the following advantages:

     Longer billets can be extruded, i.e. for a given extrusion ratio longer sections can
     be produced.
     Higher extrusion ratio can be used.
     Extrusion temperatures are lower.
     Extrusion speeds are higher.
     Uniform metallurgical structure is achieved.

However, since the extruded product has to pass through the hollow stem of the ram the
size of the section is restricted. In fact, surprisingly, little use has been made of the
indirect process.




TALAT 1302                                                              14
1302.03 Literature

Lange, K. (Ed): "Handbook of Metal Forming", Ch. 16: "Hot extrusion" pp. 16.1 -
       16.67. McGraw-Hill 1985.

Proceedings of the 5th International Aluminium Extrusion Technology Seminar. Vol. I
       & II, Chicago May 1992. The Aluminium Association

Reiso, O. "The Effect of Microstructure on the Extrudability of Some Aluminium
        Alloys" Dr. Techn. Thesis, Norwegian Institute of Technology, Trondheim
        1992

Proceedings of other ET Conferences in USA

Spencer, H.: Aluminium Extrusions - a Technical Design Guide. The Shapemakers
       Information Service, Broadway House, Birmingham




TALAT 1302                           15
1302.04 List of Figures

Figure No.   Figure Title (Overhead)
1302.00.01   Forward or Direct Extrusion
1302.00.02   Extrusions
1302.00.03   Rectangular Billet
1302.00.04   Indirect Extrusion
1302.01.01   Typical Die Tooling Assembly for Forward Extrusion
1302.01.02   Relative Extrudability of Aluminium Alloys
1302.01.03   Methods for Slowing or Speeding Metal Flow Through an Extrusion Die
1302.01.04   The Process - An Overview
1302.01.05   Cylindrical Billet
1302.01.06   A Guide to Minimum Section Thickness for 6063 Extrusions
1302.01.07   Shape Factor Values (Formula)
1302.01.08   Extrudability of Various Alloys
1302.01.09   Extruding Tubing with Die and Mandrel
1302.01.10   Extrusion of Hollow Section
1302.01.11   Designing Extrusion with Improved Stiffness
1302.01.12   Audi A8 Aluminium Spaceframe
1302.01.13   Example of Tool Costs for Extrusions
1302.01.14   Hollow Sections Produced Using Rectangular Container
1302.02.01   Composition of some AlMgSi Alloys
1302.02.02   Chemical Composition of Some Aluminium Alloys Produced as Extrusions
1302.02.03   Properties of Some Aluminium Alloys Produced as Extrusions
1302.02.04   Phase Diagram for AlMgSi Alloys
1302.02.05   Flow of Metal in Direct Extrusion




TALAT 1302                          16

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TALAT Lecture 1302: Aluminium Extrusion: Alloys, Shapes and Properties

  • 1. TALAT Lecture 1302 Aluminium Extrusion: Alloys, Shapes and Properties 16 pages, 23 figures Basic Level prepared by Roy Woodward, Aluminium Federation, Birmingham Objectives: − to provide sufficient information on the extrusion of aluminum and the performance of extruded products to ensure that students, users and potential users of those products can understand the fabrication features that affect properties and ecomomics. − to show how in consequence alloy choice for any end application depends not only on the characteristics required for that end use but also on production requirements. Prerequisites: − General knowledge in materials engineering − Some knowledge about aluminium alloy constitution and heat treatment Date of Issue: 1994  EAA - European Aluminium Association TALAT1302
  • 2. 1302 Aluminium Extrusion: Alloys, Shapes and Properties Table of contents 1302 Aluminium Extrusion: Alloys, Shapes and Properties...................................2 1302.00 Introduction...................................................................................................2 1302.01 The Extrusion Process ...................................................................................4 1302.02 The 6000 Series Alloys ................................................................................11 1302.03 Literature......................................................................................................15 1302.04 List of Figures ..............................................................................................16 1302.00 Introduction The term extrusion is usually applied to both the process, and the product obtained, when a hot cylindrical billet of aluminium is pushed through a shaped die (forward or direct extrusion, see Figure 1302.00.01). The resulting section can be used in long lengths or cut into short parts for use in structures, vehicles or components. Also, extrusions are used for the starting stock for drawn rod, cold extruded and forged products (Figure 1302.00.02). While the majority of the many hundreds of extrusion presses used throughout the world are covered by the simple description given above it should be noted that some presses accommodate rectangular shaped billets for the purpose of producing extrusions with wide section sizes (Figure 1302.00.03). Other presses are designed to push the die into the billet. This latter modification is usually termed "indirect" extrusion (Figure 1302.00.04). DIE EXTRUSION BILLET RAM alu Forward or Direct Extrusion 1302.00.01 Training in Aluminium Application Technologies TALAT 1302 2
  • 3. The versatility of the process in terms of both alloys available and shapes possible makes it one of the most valued assets in helping the aluminium producer supply users with solutions to their design requirements. MAIN PROCESS PRODUCT GROUPS GENERIC ALLOYS SYSTEM OF PROFILES STRUCTURAL SECTIONS AlMgSi (AA6060) FORMED SECTIONS HOT EXTRUSION OF PROFILES MACHINED PARTS AlSi1MgMn TUBES CUT (AA6082) BLANKED ROD MILLED AlMn1 COLD DRAWN SECTIONS (AA3103) AlSi1Mg IMPACT AND COLD EXTRUDED (AA6351) AlZn5.5MgCu FORGINGS (AA7075) alu Extrusions 1302.00.02 Training in Aluminium Application Technologies alu Training in Aluminium Application Technologies Rectangular Billet 1302.00.03 DIE SEALING PLATE RAM EXTRUSION BILLET alu Indirect Extrusion 1302.00.04 Training in Aluminium Application Technologies TALAT 1302 3
  • 4. 1302.01 The Extrusion Process The fundamental features of the process are as follows: A heated billet cut from DC cast log (or for small diameters from larger extruded bar) is located in a heated container, the actual temperatures of both varying according to alloy and other operation conditions discussed later, but usually around 450 °C - 500 °C. At these temperatures the flow stress of the aluminium alloys is very low and by applying pressure by means of a ram to one end of the billet the metal flows through the steel die, located at the other end of the container to produce a section, the cross sectional shape of which is defined by the shape of the die (Figure 1302.01.01). The maximum length of the section depends on the volume of the billet (cross-section x length) and on the extrusion ratio, i.e. the ratio of cross-section of the billet to the cross-section of the extrusion. When it is necessary to obtain very long length of section, as for instance in electrical conductors, it is possible to introduce successive billets into the container and produce a continuous product. The interaction between alloy composition, conditions of billet and container, extrusion ratio and extrusion speed affects metal flow and the resulting properties and structure of the section and its surface finish, while the actual die configuration and the condition and shape of the bearing surfaces over which the hot aluminium flows and the die temperature also contribute. When we add the way in which the section is cooled and handled after leaving the die it can be seen that a process described as being like "squeezing tooth paste from a tube" does have a quite complex set of parameters to control but at the same time a wide variety of means to produce the characteristics required from the product. The importance of the process to the aluminium industry and its customers is well illustrated by the fact that over the past 20 years, at four year intervals, five international conferences have been held in USA at which some 600 technical papers on the extrusion of aluminium and its alloys have been presented. A sixth such conference will be held in 1996. Few, if any aspects of the process, the products, their uses, their recycling and predictions for their future have failed to receive attention. EXTRUSION PLATTEN SUB-BOLSTER BOLSTER PLATTEN PRESSURE BACKER RING DIE DUMMY BLOCK STEM BILLET DIE RING CONTAINER LINER CONTAINER DIE SLIDE alu Typical Die Tooling Assembly For Forward Extrusion 1302.01.01 Training in Aluminium Application Technologies TALAT 1302 4
  • 5. The temperature at which the section leaves the die must not be so high as to cause cracking of the product surface or cause it to develop "pick-up" which could make its appearance unacceptable. The emerging temperature is affected by many of the factors mentioned above and its control is, therefore, possible in a number of ways. Since for economic reasons it is desirable to extrude as fast as possible, thus obtaining maximum output from the press, much attention has been paid to the design of the bearings and to various die cooling techniques so that the temperature build up in the extruding metal caused by metal deformation and friction is kept to a minimum and/or reduced by cooling the die itself or the emerging product. All aluminium alloys can be extruded but some are less suitable than others, requiring higher pressures, allowing only low extrusion speeds and/or having less than acceptable surface finish and section complexity. The term "extrudability" is used to embrace all of these issues with pure aluminium at one end of the scale and the strong aluminium/zinc/magnesium/copper alloys or other (see Figure 1302.01.02). Because of the mentioned complex interaction of process factors this rating can be seen to be arbitary! ALLOY RATING ALLOY RATING EC 150 6063 100 1060 150 6066 40 1100 150 6101 100 1150 150 6151 70 2011 15 6253 80 2014 20 6351 60 2024 15 6463 100 3003 100 6663 100 5052 80 7001 7 5083 20 7075 10 5086 25 7079 10 5154 50 7178 7 5254 50 5454 50 5456 20 6061 60 alu Relative Extrudability of Aluminium Alloys 1302.01.02 Training in Aluminium Application Technologies Depending on the size of the section and the size of the billet it is possible to extrude more than one section per die, up to say eight, thus greatly increasing the press output. The exact location of the section shapes around the axis is important to ensure that the sections all emerge at the same speed in order to facilitate handling. Also, even for single hole dies the metal flow through the die must be controlled by die bearing design and section orientation with respect to the die axis so that uniform speed by all parts of the section is achieved (Figure 1302.01.03); otherwise the section will deflect on emerging and suffer shape distortion. When the sections of heat treated alloys leave the die they can, depending on the alloy and section thickness, be quenched either in water or by air cooling, thus rendering a "solution heat treatment", or be taken from the press for formal solution heat treatment in a furnace. After either of these operations the sections receive a stretch of between 1 and 2% to remove residual stress followed by artificial ageing to stabilize their properties. The temper designations for extrusion products are numerous and a number of typical ones are shown; the most common are T4, T5 and T6. TALAT 1302 5
  • 6. BACK BACK TAPER TAPER ORIGINAL ORIGINAL BEARING BEARING CHOKE PRESENT BEARING RELIEF DEGREE OF BACK TAPER BACK TAPER CHOKE UNDERCUT UNDERCUT NEEDED 0.003 RELIEF CHOKED TO SLOW METAL FLOW RELIEVED TO SPEED METAL FLOW alu Methods for Slowing or Speeding Metal Flow 1302.01.03 Training in Aluminium Application Technologies Through an Extrusion Die THE PLANT FOR DESPATCH PACKING HEAT TREATMENT SAW BILLET-HEATER COOLING & LOG SHEAR PRESS PULLER COOLING TABLE LOGS BILLETS STRETCHER STACKER PRE HEATING OF DIES alu The Process - An Overview 1302.01.04 Training in Aluminium Application Technologies CIRCUMSCRIBING CIRCLE DIAMETER alu Training in Aluminium Application Technologies Cylindrical Billet 1302.01.05 TALAT 1302 6
  • 7. A typical extrusion plant layout is shown in Figure 1302.01.04. Press load capacities range from a few hundred tonnes to as high as 20.000 tonnes although the majority range between 1.000 and 3.000 tonnes. Billet sizes cover the range from 50 mm diameter to 500 mm with length usually about 2-4 times the diameter and while most presses have cylindrical containers a few have rectangular ones for the production of wide shallow sections. Obviously the overall dimensions of a section are related to the billet diameter (Figure 1302.01.05), and the minimum section thickness relates to the location of the section within this "circumscribing circle", the complexity of the section and the alloy see Figure 1302.01.06, Figure 1302.01.07, and Figure 1302.01.08). The minimum thickness possibly is about 0.5 mm. With these limitations taken into account it is no exaggeration to say that a designer can have any shape he requires, a claim supported by the fact that some extruders have over 100,000 dies at their disposal. In designing a section to meet his requirements a user is well advised to consult at an earlier stage with the suppliers. Both solid and hollow sections can be supplied by any extrusion plant, but there are differences in the philosophy of design and manufacture of the dies for the latter which affect both cost and quality of the product; also some structural features of the product may require modification for better extrudability. METAL THICKNESS mm 5.00 HOLLOWS & SEMI HOLLOWS DEEP CHANNELS 4.00 MEDIUM DEEP CHANNELS, ANGLES & FLATS. 3.00 2.00 1.00 CIRCUMSCRIBING 50 100 150 200 250 300 CIRCLE DIAMETER mm alu A Guide to Minimum Section Thickness for 1302.01.06 Training in Aluminium Application Technologies 6063 Extrusions SECTION TYPE CCD mm THICKNESS mm SHAPE FACTOR 142 2.5 300 70 1.5 500 112 5.0 152 142 SOLID 15 70 SOLID 30 50 3.0 247 50 1.5 494 210 3.0 190 210 2.0 285 140 2.0/6.0 183 40 2.0/1.5 430 PERIPHERY alu Shape Factor Values SHAPE FACTOR = CROSS SECTION AREA 1302.01.07 Training in Aluminium Application Technologies TALAT 1302 7
  • 8. STRENGTH (MPa) Rp 0.2 AlZn6MgCu (7000 series) Rm 500 MIN. WALL THICKNESS (mm) 400 10 9 AlSi1MgMn (6082) 8 300 7 6 200 5 AlMgSi (6060) 4 3 100 Al 99.5 2 1 0 0 0 50 100 150 EXTRUDABILITY INDEX EXTRUSION SPEED 0.5 - 2 M/min 10 - 80 M/min 20 - 100 M/min alu Extrudability of Various Alloys 1302.01.08 Training in Aluminium Application Technologies Simple hollow sections such as rounds, squares and ovals can be produced from a hollow billet using a mandrel (Figure 1302.01.09). Here the product has a uniform structure across the section. More complex sections are made using bridge or port hole dies in which the metal flows around a shaped bridge and joins again by hot pressure welding in a mixing chamber (Figure 1302.01.10). The design of such dies requires a great deal of experience although the use of C.A.D. and the understanding of metal flow is helping to add "science" to what is in effect an "art". Because the deformation experienced by the "welds" is different from that received by other parts of the cross section a metallurgical examination of the cross section reveals differences in grain structure at the welds and if the mixing chamber design and extrusion conditions are less than optimum the weld lines can be obvious on the section surface. When properly made, however, the difference in structure causes no significant reduction in section performance, although mechanical tests across the weld do show how some reduction in both strength and elongation do occur. Hollow sections made from bridge dies are used in critically stressed applications, the accumulated experience of both producers and users guaranteeing their integrity when produced under the controlled conditions obtaining in reliable producers plants. RAM DIE LINER MANDREL TUBING BILLET alu Extruding Tubing with Die and Mandrel 1302.01.09 Training in Aluminium Application Technologies TALAT 1302 8
  • 9. WELD AREA PRESSURE EXTRUDED TUBE DIE MANDREL NOSE SOLID BILLET BRIDGE alu Extrusion of Hollow Section 1302.01.10 Training in Aluminium Application Technologies Steel- and Aluminium Girders with the same Bending Stiffness Steel Aluminium Aluminium Aluminium appro. 50% increased increased torsional lower weight torsional stiffness and vs. steel stiffness integrated functions alu Training in Aluminium Application Technologies Designing Extrusions with Improved Stiffness 1302.01.11 The ease with which aluminium alloys can be extruded to complex shapes makes valid the claim that it allows the designer to "put metal exactly where it is needed", a requirement of particular importance with a relatively expensive material. Furthermore, this flexibility in design makes it easy, in most cases, to overcome the fact that aluminium and its alloys have only 1/3 the modulus of elasticity of steel (Figure 1302.01.11). Since stiffness is dependent not only on modulus but also on section geometry it is possible, by deepening an aluminium beam by around 1,5 times the steel component it is intended to replace, to match the stiffness of the steel at half the weight. Also, at little added die cost, features can be introduced into the section shape which increase torsional stiffness and provide grooves for say fluid removal, service cables, anti-slip ridges etc. Such features in a steel beam would require joining and machining, thus adding to the cost and narrowing the gap between initial steel and aluminium costs. Good examples of this use of the flexibility of extrusions in design are found in the use by AUDI of over a hundred different extruded shapes in space frame construction (Figure 1302.01.12). The cost of extrusion dies obviously has to be taken into account TALAT 1302 9
  • 10. in costing the use of extrusions but because the operating temperatures for aluminium are low compared with the temperatures at which steels can be used, viz around 500 °C, no special steels are required for dies thus keeping material costs low (Figure 1302.01.13). Obviously, very complex wide hollow dies are much more expensive than those for small solid sections but the latter cost as little as a few hundred ECU, and while the former might cost several thousand ECU the advantages to be gained by their use, particularly when large quantities of section from any one die are required, can readily counter that cost, as is well demonstrated by the extensive use of large, very complex sections in rail and road transport (Figure 1302.01.14). Audi A8 Aluminium Spaceframe alu Audi A8 Aluminium Spaceframe 1302.01.12 Training in Aluminium Application Technologies Tool Cost ( US $ ) $ $ 1,5 00 800 20 mm 20 mm 130 mm 50 mm $ 00 1,5 50 mm 100 mm $ 00 1,5 50 mm 130 mm alu Training in Aluminium Application Technologies Example of Tool Costs for Extrusions 1302.01.13 TALAT 1302 10
  • 11. 1100 4 570 1 570 100 800 45 5 45 85 270 260 500 Dimensions in mm. alu Hollow Sections Produced Using Rectangular Container 1302.01.14 Training in Aluminium Application Technologies 1302.02 The 6000 Series Alloys As indicated in earlier sections all aluminium alloys can be extruded. However, while large quantities of pure aluminium are extruded for production of electrical conductors, strong alloys in the 2000, 7000 and 8000 series used for spars and stringers in airframe construction and large sections in the 5000 series employed in marine structures, the biggest share of the extrusion market is taken by the 6000, AlMgSi series (see Figure 1302.02.01, Figure 1302.02.02 and Figure 1302.02.03). This group of alloys have an attractive combination of properties, relevant to both use and production and they have been subject to a great deal of R & D in many countries, mainly UK, USA, Germany, France, Switzerland and Japan. The result is a set of materials ranging in strength from 150 Mpa to 350 Mpa, all with good toughness and formability. They can be extruded with ease and their overall "extrudability" is good but those containing the lower limits of magnesium and silicon e.g. 6060 and 6063 extrude at very high speeds - up to 100 m/min with good surface finish, anodising capability and maximum complexity of section shape combined with minimum section thickness. Their strengths are at the bottom end of the range, and they find wide use in architectural applications where shape and finish are more important than strength. Also, the elastic modulus of all the 6000 series is the same, as is their fatigue strength when welded and these two facts coupled with the other attractive features of the 6063/6005A type make them of increasing value in transport applications. Here stiffness and fatigue often override strength as a requirement, and the complexity of thin sections possible with the lower strength versions means that maximum advantage can be taken of the reduction in welding costs made possible by their use. Rail coach construction reflects this situation and it is in this application that full advantage has been taken of the aforementioned use of rectangular containers to allow production of wide sections. The stronger 6082 type alloys are used for members where tensile strength and impact resistance as well as TALAT 1302 11
  • 12. stiffness and fatigue are important. All of the 6000 series alloys suffer a reduction of strength at the fusion welds used in construction and this has to be taken into account in design. There is ample data to show how this is done. %Mg AA 6082 1.2 1.0 AA 6063 0.8 0.6 0.4 AA6005A AA 6060 0.2 %Si 0.2 0.4 0.6 0.8 1.0 1.2 alu Composition of some AlMgSi Alloys 1302.02.01 Training in Aluminium Application Technologies ALLOY COMPOSITION % (Remainder Al) BS 1474 OTHERS (1987) Si Fe Cu Mn Mg Cr Ni Zn Ti EACH TOTAL 0.20- 0.45- 6063 0.60 0.35 0.10 0.10 0.90 0.10 - 0.10 0.10 0.05 0.15 0.30- 0.15- 0.60- 6063A 0.60 0.35 0.10 0.15 0.90 0.05 - 0.15 0.10 0.05 0.15 0.70- 0.40- 0.60- 6082 1.30 0.50 0.10 1.00 1.20 0.25 - 0.20 0.10 0.05 0.15 0.30- 0.40- 6101A 0.40 0.05 - - - - - 0.03 0.15 0.70 0.90 0.20- 0.45- 6463 0.15 0.20 0.05 - - 0.05 - 0.05 0.15 0.60 0.90 0.50- 3.90- 0.40- 0.20- 0.15- 0.50 0.10 0.40 0.25 0.05 0.15 2014A 0.90 5.00 1.20 0.80 0.20 Ti + Zr Chemical Composition of Some Aluminium Alloys alu Produced as Extrusions 1302.02.02 Training in Aluminium Application Technologies TEMPER MAX. 0.2% PS ULTIMATE % ELONGATION N/mm22 STRENGTH ALLOY THICKNESS 2 5.65 So 50 mm mm N/mm 2 F 200 - 100 13 12 T4 150 70 130 16 14 6063 T5 25 110 150 8 7 T6 150 160 195 8 7 T4 25 90 150 14 12 6063A T5 25 160 200 8 7 T6 25 190 230 8 7 F 200 - 110 13 12 6082 T4 150 120 190 16 14 T5 6 230 270 - 8 T6 20 255 295 8 7 6101A T6 - 170 200 10 8 T4 50 75 125 16 - 6463 T6 50 160 185 10 - T4 20 230 370 11 10 2014A T6 20 370 435 7 6 So = cross-sectional area Source: Aluminium Extrusions - a technical design guide, The Shapemakers, UK, 1991 alu Properties of Some Aluminium Alloys 1302.02.03 Training in Aluminium Application Technologies Produced as Extrusions A further advantage of the use of 6063/6005A type alloys lies in their attractive response to the thermal treatments required to provide their properties. All of the 6000 series TALAT 1302 12
  • 13. alloys have to be quenched from the "solution heat treatment" temperature in order to achieve their optimum mechanical properties, the critical temperature range depending on the actual composition. Also the cooling rate from the S.H.T. temperature is important. For the 6063 types the range of temperature from which quenching takes place is wide and for most sections cooling in air provides an adequate rate, particularly if forced air cooling is employed. While the stronger, 6082 types can be quenched at the press, i.e. the heat generated in the extrusion process is sufficient to provide S.H.T. the alloys are quench-sensitive and require water cooling for other than thin sections. The gentle rates occurring with air cooling have the added advantage of reducing or avoiding any distortion of the sections (see Figure 1302.02.04). [°C] 700 600 500 400 AA6060 AA6082 T6 180 - 220 255 - 330 R p0.2 [Mpa] T6 200 - 260 295 - 345 Rm [Mpa] 300 WEIGHT % Mg2Si 0 0.5 1.0 1.5 2.0 alu Phase Diagram for AlMgSi Alloys 1302.02.04 Training in Aluminium Application Technologies Metal flow during the extrusion (in forward extrusion) is such that the surface of the extruded product does not derive from the billet surface but is created as a result of shear across a "dead metal zone" (1302.02.05). It is, therefore, not necessary to remove the billet cast surface prior to extrusion (in the indirect process there is no dead metal zone and the product surface is created from the billet surface thus requiring that the billet be scalped). At the beginning of the forward process little work has gone into the product and, depending on section size, alloy thickness of section, etc. a portion of the extrusion is cut off as a discard to avoid supplying material with reduced properties. Also care is taken to avoid any back-end defects at the end of the cycle. These effects are well understood and the precautions needed to avoid them affecting material supplied to the user are established. TALAT 1302 13
  • 14. DEAD METAL ZONE CONTAINER RAM BILLET PRODUCT PRESSURE PAD DIE BACKUP PLATE alu Flow Metal in Direct Extrusion 1302.02.05 Training in Aluminium Application Technologies In forward or direct extrusion the ram pressure not only has to deform the metal but also overcome the friction between the billet and the container. With the indirect process the billet and container do not move relative to each other and so all of the available press load is used for deformation. In consequence of these differences indirect extrusion has the following advantages: Longer billets can be extruded, i.e. for a given extrusion ratio longer sections can be produced. Higher extrusion ratio can be used. Extrusion temperatures are lower. Extrusion speeds are higher. Uniform metallurgical structure is achieved. However, since the extruded product has to pass through the hollow stem of the ram the size of the section is restricted. In fact, surprisingly, little use has been made of the indirect process. TALAT 1302 14
  • 15. 1302.03 Literature Lange, K. (Ed): "Handbook of Metal Forming", Ch. 16: "Hot extrusion" pp. 16.1 - 16.67. McGraw-Hill 1985. Proceedings of the 5th International Aluminium Extrusion Technology Seminar. Vol. I & II, Chicago May 1992. The Aluminium Association Reiso, O. "The Effect of Microstructure on the Extrudability of Some Aluminium Alloys" Dr. Techn. Thesis, Norwegian Institute of Technology, Trondheim 1992 Proceedings of other ET Conferences in USA Spencer, H.: Aluminium Extrusions - a Technical Design Guide. The Shapemakers Information Service, Broadway House, Birmingham TALAT 1302 15
  • 16. 1302.04 List of Figures Figure No. Figure Title (Overhead) 1302.00.01 Forward or Direct Extrusion 1302.00.02 Extrusions 1302.00.03 Rectangular Billet 1302.00.04 Indirect Extrusion 1302.01.01 Typical Die Tooling Assembly for Forward Extrusion 1302.01.02 Relative Extrudability of Aluminium Alloys 1302.01.03 Methods for Slowing or Speeding Metal Flow Through an Extrusion Die 1302.01.04 The Process - An Overview 1302.01.05 Cylindrical Billet 1302.01.06 A Guide to Minimum Section Thickness for 6063 Extrusions 1302.01.07 Shape Factor Values (Formula) 1302.01.08 Extrudability of Various Alloys 1302.01.09 Extruding Tubing with Die and Mandrel 1302.01.10 Extrusion of Hollow Section 1302.01.11 Designing Extrusion with Improved Stiffness 1302.01.12 Audi A8 Aluminium Spaceframe 1302.01.13 Example of Tool Costs for Extrusions 1302.01.14 Hollow Sections Produced Using Rectangular Container 1302.02.01 Composition of some AlMgSi Alloys 1302.02.02 Chemical Composition of Some Aluminium Alloys Produced as Extrusions 1302.02.03 Properties of Some Aluminium Alloys Produced as Extrusions 1302.02.04 Phase Diagram for AlMgSi Alloys 1302.02.05 Flow of Metal in Direct Extrusion TALAT 1302 16