Search Results (20)

This study presents the results of research on the influence of different contents of copper in aluminium alloys based on the 6xxx series on mechanical and structural properties. The investigation started with the alloying, and casting four billet variants with different copper content—0.8% Cu; 2B—1% Cu; 3A—1.2% Cu; and 3B—1.4% Cu. The prepared materials were homogenised and extruded on a 500T horizontal press with two different process temperatures and ram speeds ranging from 1 mm/s to 9 mm/s. After heat treating to the T6 and T5 tempers, their mechanical properties were tested. On this basis, the two most promising alloys 2A and 3B were selected and subjected to further tests. After extrusion and heat treatment of the profiles (to F, T1, T2, T5, and T5510), their mechanical properties were determined to select the preferred process parameters. Finally, a structural test based on crystallographic orientation based on the EBSD technique and TEM observations allowed for the characterisation of grain size, dispersoids, and phase analysis. Bright-field (BF) analysis allowed us to compare the deformed areas for T1, T5, and T5510 temperatures. The results showed significant growth in the mechanical properties of all the subjected alloys, and the best properties were shown for a Cu content of 1.4% with a tensile strength of 460 MPa and an elongation of 16% (T5510 tempering). The structural test showed an average grain size of 18 µm to 23 µm and solid solution decomposition differences for different heat-treating parameters. Full article

This work investigated material extrusion additive manufacturing (MatEx AM) of specialized fluoroelastomer (FKM) compounds for applications in rubber seals and gaskets. The influence of a commercially available perfluoropolyether (PFPE) plasticizer on the printability of a control FKM rubber compound was studied using a custom-designed ram material extruder, Additive Ram Material Extruder (ARME), for printing fully compounded thermoset elastomers. The plasticizer’s effectiveness was assessed based on its ability to address challenges such as high compound viscosity and post-print shrinkage, as well as its impact on interlayer adhesion. The addition of the PFPE plasticizer significantly reduced the FKM compound’s viscosity (by 70%) and post-print shrinkage (by 65%). While the addition of the plasticizer decreased the tensile strength of the control compound, specimens printed with the plasticized FKM retained 34% of the tensile strength of compression-molded samples, compared to only 23% for the unplasticized compound. Finally, the feasibility of seals and gaskets manufacturing using both conventional and unconventional additive manufacturing (AM) approaches was explored. A hybrid method combining AM and soft tooling for compression molding emerged as the optimal method for seal and gasket fabrication. Full article

The large differential-thermal extrusion (LDTE) process, a novel approach for efficiently fabricating a high-strength Mg-10.3Gd-4.4Y-0.9Zn-0.7Mn (wt.%) alloy, is introduced in this work. Unlike typical isothermal extrusion processes, where the ingot and die temperatures are kept the same, LDTE involves significantly higher ingot temperatures (~120 °C) compared to the die temperature. For high-strength Mg-RE alloys, the maximum isothermal extrusion ram speed is normally limited to 1 mm/s. This research uses the LDTE process to significantly increase the ram speed to 2.0 mm/s. The LPTE-processed alloy possesses a phase composition that is similar to that of isothermal extruded alloys, including α-Mg, 14H-type long-period stacking ordered (LPSO) and β-Mg₅(Gd, Y) phases. The weakly preferentially oriented α-Mg grains in the LDTE-processed alloy have $<10\overline{1}0>$_Mg//ED fibrous and <0001>_Mg//ED anomalous textures as their two main constituents. After isothermal aging, high quantitative densities of prismatic β′ and basal γ′ precipitates are produced, which have the beneficial effect of precipitation hardening. With a yield tensile strength of 344 MPa, an ultimate tensile strength of 488 MPa, and an elongation of 9.7%, the alloy produced by the LDTE process exhibits an exceptional strength–ductility balance, further demonstrating the potential of this method for efficiently producing high-strength Mg alloys. Full article

Extrusion-based 3D concrete printing (E3DCP) has been appreciated by academia and industry as the most plausible candidate for prospective concrete constructions. Considerable research efforts are dedicated to the material design to improve the extrudability of fresh concrete. However, at the time of writing this paper, there is still a lack of a review paper that highlights the significance of the mechanical design of the E3DCP system. This paper provides a comprehensive review of the mechanical design of the E3DCP extruder system in terms of the extruder system, positioning system and advanced fittings, and their effects on the extrudability are also discussed by relating to the extrusion driving forces and extrusion resistive forces which may include chamber wall shear force, shaping force, nozzle wall shear force, dead zone shear force and layer pressing force. Moreover, a classification framework of the E3DCP system as an extension of the DFC classification framework was proposed. The authors reckoned that such a classification framework could assist a more systematic E3DCP system design. Full article

This study deals with the microstructure, mechanical, and wear properties of the extruded ZK60 matrix composites strengthened with 45 µm, 15% silicon carbide particle (SiC) and 760 nm, 0.2–0.5% aluminium nitride (AlN) nanoparticle reinforcements. First, the reinforcement elements of the composites, SiC and AlN mixtures were prepared in master-magnesium powder, and compacts were formed under 450 MPa pressure and then sintered. Second, the compacted reinforcing elements were placed into the ZK60 alloy matrix at the semi-solid melt temperature, and the melt was mixed by mechanical mixing. After the melts were mixed for 30 min and a homogeneous mixture was formed, the mixtures were poured into metal moulds and composite samples were obtained. After being homogenized for 24 h at 400 °C, the alloys were extruded with a 16:1 deformation ratio at 310 °C and a ram speed of 0.3 mm/s to create final composite samples. After microstructure characterization and hardness analysis, the dry friction behavior of all composite samples was investigated. Depending on the percentage ratios of SIC and AlN reinforcement elements in the matrix, it was seen that the compressive strength and hardness of the composites increased, and the friction coefficient decreased. While the wear rate of the unreinforced ZK60 alloy was 3.89 × 10⁻⁵ g/m, this value decreased by 26.2 percent to 2.87 × 10⁻⁵ g/m in the 0.5% AlN + 15% SiC reinforced ZK 60 alloy. Full article

This article presents the outcome of research on modelling the process of the extrusion of crystalline dry ice. The purpose of this process is to densify the material and obtain pellets of several millimeters in diameter. This reduces the sublimation rate in ambient conditions of the material whose temperature in a solid state is 195 K. A lower sublimation rate means a reduction of the loss of product in its final applications, which include refrigeration and reduction of atmospheric emissions of gaseous CO₂. A ram-type extruder was considered in this analysis, in which dry ice was extruded through a single-hole die of varying geometry. The article presents the results of numerical analyses of the extrusion process, using a simulation method based on the Smoothed Particle Hydrodynamics (SPH) approach. The results from simulations were verified by the experimental data in terms of the maximum force required to complete the process, in order to assess the applicability of the proposed method in further research on dry ice compression. Full article

The work in this paper concerns an analytical model for quantitatively describing the bending behaviour of aluminium profiles produced in a novel extrusion process: the differential velocity sideways extrusion (DVSE), in which two opposing rams with a velocity of $v_1$ and $v_2$ were employed, respectively. The analytical model was built on the basis of the upper bound theorem utilising a general streamline equation controlled by a shape factor n, and the curvature was calculated using the material flow velocity gradient across the die exit orifice. The predicted material flow velocity across the die exit orifice, and extrudate curvature agreed well with the finite element (FE) modelling results, which were found to be irrespective of the shape factor n of the streamline equation. For a given extrusion ratio, the minimum value of n = 2 leads to the minimum and closest theoretical extrusion pressure, the n value for obtaining the best approximated mean effective strain of the extruded profile increases with the increase of the velocity ratio $v_2/v_1$, and the value of n = 3.5 gives the closest mean effective strain as a whole. Full article

In this paper, the Conditional Average Estimator artificial neural network (CAE ANN) was used to analyze the influence of chemical composition in conjunction with selected process parameters on the yield strength and elongation of an extruded 6082 aluminum alloy (AA6082) profile. Analysis focused on the optimization of mechanical properties as a function of casting temperature, casting speed, addition rate of alloy wire, ram speed, extrusion ratio, and number of extrusion strands on one side, and different contents of chemical elements, i.e., Si, Mn, Mg, and Fe, on the other side. The obtained results revealed very complex non-linear relationships between all of these parameters. Using the proposed approach, it was possible to identify the combinations of chemical composition and process parameters as well as their values for a simultaneous increase of yield strength and elongation of extruded profiles. These results are a contribution of the presented study in comparison with published research results of similar studies in this field. Application of the proposed approach, either in the research and/or in industrial aluminum production, suggests a further increase in the relevant mechanical properties. Full article

Rammed earth (RE) is a low-tech recyclable building material with good heat storage and moisture absorption performance that can better maintain the stability of the indoor thermal environment and improve indoor comfort. With innovations in and the development of new technology, the field of rammed earth construction technology is gradually expanding. However, deficiencies in the thermal insulation of traditional rammed earth structures make it impossible for them to meet China’s building energy codes in cold regions. This study constructs a comprehensive evaluation index of the thermal performance of rammed earth walls that is based on the heat transfer mechanism, optimizing the thickness of the boundary conditions of the building interior’s design temperature, as well as the energy demand and economic efficiency. This research also offers a new design for the thermal insulation of rammed earth construction by combining the building energy savings design code with WUFI Pro software. This study demonstrates that the optimum thickness of rammed earth construction in Beijing is about 360 mm, the thickness of extruded polystyrene board (XPS) is 50 mm (for public buildings) and 70 mm (for residential buildings), and the structural form of external insulation offers the highest performance benefit. In addition, this work also evaluates the risk of condensation inside composite rammed earth construction, finding that there is a risk of condensation on the exterior side of the wall and at the interface between the insulation panels and rammed earth wall, thus requiring an additional moisture-proof layer. In this study, thermal mass and insulation are fully considered and a design strategy for rammed earth construction given quantitatively, providing a theoretical basis for the application of rammed earth materials in cold regions. Full article

The surface quality control of extruded products is a critical concern in the home appliance manufacturing industry owing to the increasing need for products with a high surface quality, in addition to the essential mechanical properties of the final product. The underlying issue with achieving high-quality extrusion products is that surface defects, especially those resulting in surface gloss differences, called white line defects, are only observed after surface treatment. In this study, we aim to investigate the cause of white line defect generation on the surface of an extruded product. Accordingly, an experimental extrusion program is established using an L-shaped die that has a noticeable change in its bearing length along the inner corner of its cross-sectional profile. Laboratory-scale experiments were performed for the L-shaped extrusion of homogenized Al 6063 alloy at various ram speeds, in order to induce surface defects, considering the production yield rate required for mass production. Subsequently, the microstructural changes near the surface failure region were investigated using an arbitrary Lagrangian–Eulerian (ALE) technique-based thermomechanical finite element (FE) analysis. To scale-up the defect observation method from laboratory-scale to production-scale manufacturing and confirm the reproducibility of the surface defect, scaled-up L-shaped extrusions were performed in an actual industrial production line. Finally, the potential cause of white line defect generation is discussed by comparing the numerical and metallurgical analyses, including the scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) observations. Full article

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. Full article

Single-screw extruders are usually operated with the screw fully filled (flood-fed mode) and not partially filled (starve-fed mode). These modes result in completely different processing characteristics, and although starve-fed mode has been shown to have significant advantages, such as improved mixing and melting performance, it is rarely used, and experimental studies are scarce. Here, we present extensive experimental research into starve-fed extrusion at feeding rates as low as 25%. We compared various operating parameters (e.g., residence time, pressure build-up, and melting performance) at various feeding rates and screw speeds. The results show a first insight into the performance of starve-fed extruders compared to flood-fed extruders. We explored starve-fed extrusion of a polyethylene material which contains a Very High Molecular Weight Polyethylene fraction (VHMWPE). VHMWPE offers several advantages in terms of mechanical properties, but its high viscosity renders common continuous melt processes, such as compression molding, ram extrusion and sintering, ineffective. This work shows that operating single-screw extruders in extreme starve-fed mode significantly increases residence time, melt temperature, and improves melting and that-in combination—this results in significant elongation of VHMWPE particles. Full article

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

An industrial press was used to consolidate compacted aluminum powder with a nominal diameter in the range of 1 µm. Direct and indirect hot-extrusion processes were used, and suitable process parameters were determined from heating conditions, ram speeds and billet temperatures. For comparison, a direct-extrusion press for hot extrusion of a conventional aluminum alloy AA 1050 was used. The extruded Al powder showed better mechanical properties and showed a thermal stability of the mechanical properties after annealing treatments. To increase the theoretical density of the directly extruded Al powder, single-hit hot-compression tests were carried out. Activation energies for hot forming were calculated from hot-compression tests carried out in the temperature range 300–580 °C, at different strain rates. Processing maps were used to demonstrate safe hot-working conditions, to obtain an optimal microstructure after hot forming of extruded Al powder. Full article

Increasing customer requirements for quality and productivity in extruding aluminum products has led to the development of different types of extrusion dies. In this study, three different types of dies, including traditional flat die, pocket die and spread die were designed to extrude complex and large-scale solid profiles. The design parameters for these dies were used from actual extrusion experience. The results obtained from steady-state simulation such as velocity, temperature, extrusion force, and die deformation were used to assess the advantages and disadvantages of the dies. Transient simulations were performed to analyze the evolution of transverse weld in the pocket and spread dies. The effects of ram speeds on the related extrusion parameters were also investigated. The research results provide useful guides for designers and engineers in selecting these types of extrusion dies. Full article