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Open AccessArticle

Modeling the Formation of Transverse Weld during Billet-on-Billet Extrusion

Mechanical and Mechatronics Engineering Department, University of Waterloo, 200 University Avenue West, Waterloo, ON N2L3G1, Canada
Rio Tinto Alcan, Arvida Research and Development Centre, Jonquiere, QC G7S4L2, Canada
Department of Materials Engineering, The University of British Columbia, 309-6350 Stores Rd, Vancouver, BC V6T1Z4, Canada
Author to whom correspondence should be addressed.
Materials 2014, 7(5), 3470-3480;
Received: 28 February 2014 / Revised: 22 April 2014 / Accepted: 24 April 2014 / Published: 30 April 2014
A comprehensive mathematical model of the hot extrusion process for aluminum alloys has been developed and validated. The plasticity module was developed using a commercial finite element package, DEFORM-2D, a transient Lagrangian model which couples the thermal and deformation phenomena. Validation of the model against industrial data indicated that it gave excellent predictions of the pressure during extrusion. The finite element predictions of the velocity fields were post-processed to calculate the thickness of the surface cladding as one billet is fed in after another through the die (i.e., the transverse weld). The mathematical model was then used to assess the effect a change in feeder dimensions would have on the shape, thickness and extent of the transverse weld during extrusion. Experimental measurements for different combinations of billet materials show that the model is able to accurately predict the transverse weld shape as well as the clad surface layer to thicknesses of 50 µm. The transverse weld is significantly affected by the feeder geometry shape, but the effects of ram speed, billet material and temperature on the transverse weld dimensions are negligible. View Full-Text
Keywords: extrusion; transverse weld; finite element method; feeder; aluminum alloys extrusion; transverse weld; finite element method; feeder; aluminum alloys
MDPI and ACS Style

Mahmoodkhani, Y.; Wells, M.; Parson, N.; Jowett, C.; Poole, W. Modeling the Formation of Transverse Weld during Billet-on-Billet Extrusion. Materials 2014, 7, 3470-3480.

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