Description and influencing the forming zone by friction extrusion through systematic die design

• Applicants: Professor Dr.-Ing. Noomane Ben Khalifa; Professor Dr.-Ing. Benjamin Klusemann
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2026
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 568467226

This proposal is concerned with the process control of rotationally assisted extrusion processes such as the Friction Extrusion Process (FEP). In the production of semi-finished products, a defined microstructure is a necessary starting point for further processing to determine the process parameters for the final product and to meet the requirements for the material properties. However, in bulk-forming processes such as extrusion, anisotropy in the mechanical properties of different materials especially aluminum alloys can always be observed. The degree of this inhomogeneity in the semi-finished products produced as a result of the directional forming process depends on the alloy and geometry. In extrusion, the microstructure and homogeneity of the material can be influenced by various process control strategies, forming parameters, and alloy development. Innovative rotation-assisted processes such as FEP can also be used to produce more homogeneous and finer-grained microstructures through friction-induced shear stresses. These fine-grained microstructures, e.g. in aluminum materials, are characterized by higher strength and improved ductility, which are particularly important factors for the design of a forming process. The research project proposed here will focus on the state variables in the forming zone, in particular through process control and systematic tool design, as well as a comparison of extrusion and FEP technology, and will therefore serve to research and optimize process technology. The aim is to gain a comprehensive understanding of the forming zone and the forming mechanisms to define and tune the process characteristics. The research project aims to use a microstructure-process parameter relationship to produce semi-finished products, such as wires for medical technology, for further forming processes, or as a base material for the additive manufacturing of lightweight components according to their required property profiles.

• DFG Programme: Research Grants