Production of sheets by hot extrusion of aluminium chips
Final Report Abstract
A new process chain consisting of hot extrusion of aluminium chips to a cylindrical open profile, with subsequent flattening and rolling for the production of sheets based on AA6060 aluminium chips was developed. The physical processes during chip welding at the individual process steps were investigated and a prediction of the weld quality was calculated using an analytical model and numerical methods. The mechanical properties as well as the microstructure of the chip-based sheets were examined and the results were compared with those obtained from sheets based on conventional cast billets. The results regarding the properties of the chip-based sheets, show a difference of 2 – 10 % compared to the cast-based sheets. Further processing of the sheets to bent components and deep drawn cups by bending and deep drawing was carried out to determine their capability for subsequent forming processes. The analysis of the bent components or deep-drawn cups shows no significant differences between the ones made of chips and those from cast material. It can be stated that their capability for further plastic forming operations is equal which makes the new process route a resource-efficient alternative for the production of aluminium sheet products.
Publications
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Predicting weld-quality in direct hot extrusion of aluminium chips. Journal of Materials Processing Technology, 274, 116294.
Kolpak, Felix; Schulze, André; Dahnke, Christoph & Tekkaya, A. Erman
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Weld Quality Determination in Aluminium Chip Extrusion. In: Proceedings of the European Aluminium Congress. Düsseldorf.
Schulze, A.; Kolpak, F.; Hering, O. & Tekkaya, A. E.
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Production and Subsequent Forming of Chip-Based Aluminium Sheets Without Remelting. International Journal of Precision Engineering and Manufacturing-Green Technology, 9(4), 1035-1048.
Schulze, André; Hering, Oliver & Tekkaya, A. Erman
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Welding of Aluminium in Chip Extrusion. The Minerals, Metals & Materials Series, 139-147. Springer International Publishing.
Schulze, André; Hering, Oliver & Erman, Tekkaya A.
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Production of Sheets by Hot Extrusion of Aluminum Chips. In: Proceedings of the International Aluminum Extrusion Technology Seminar. Orlando.
Schulze, A.; Dahnke, C. & Tekkaya, A. E.
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Bleche aus stranggepressten Aluminiumspänen: Herstellung, Charakterisierung und Umformbarkeit. Dissertation, Shaker Verlag, Reihe Dortmunder Umformtechnik 118. ISBN 978-3-8440-8968-4
Schulze, A.
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Direktes Aluminiumrecycling durch Spänestrangpressen. Aluminium Praxis 28, Ausgabe 5 2023 S. 36-37.
Schulze, A. & Tekkaya, A. E.
