Proceedings of the 6th Aluminum Extrusion Technology Seminar (1996)

ET SEMINAR PROCEEDINGS

Chicago, Illinois USA
May 14-17, 1996

VOLUME I – Brief Contents

  • Extrusion Process and Equipment
  • Billet Process and Equipment

 

  • Creativity and Technology

 EXTRUSION PROCESS AND EQUIPMENT

  • The Effect of Cooling Rate After Homogenization and Billet Preheating Practice on Extrudability and Section Properties Part 1: Extrudability and Mechanical Properties
  • Metallurgical Speed Limitations During the Extrusion of Al-Mg-Si Alloys

Equipment

  • A Paradigm Shift in Aluminum Extrusion Processes Due to Long Metal Handling
  • The Ten-Second Dead Cycle
  • How to Operate Extrusion Presses Well

Process and Process Control

  • Isothermal and Isopressure Extrusion — Results of Process Optimization in Various Extrusion Plants
  • Improvement of Aluminum Extrusion Profiles for Architecture
  • Theoretical and Practical Considerations for the Applications of “Fuzzy Logic” in the Aluminum Extrusion Industry
  • Surface Defects on 6XXX Alloy Extrusions
  • Flow Formulation FE Metal Forming Analysis with Boundary Friction Via Penalty Function
  • Isothermal Extrusion of Aluminum Alloys by Employing Force-Ram Speed Feedback
  • A New Measurement and Control System for Isothermal Extrusion
  • The Importance of a Powerful Press Control System to Attain and Improve Quality and Delivery Performance
  • Increasing Extrusion Plant Productivity and Quality
  • Integration of the Ageing Cycle into an Automated Extrusion Line
  • Modernizing the Extrusion Press and Handling System: Adapting New Technologies to Older Plants

Influence of Billet Temperature

  • Mr. Profile’s New Extrusion Line
  • Tapered heating and the “PYRAL” Integrated System
  • Taper Quenching: A Cost-Effective Tapering Method for Isothermal Extrusion
  • Induction Billet Heating — An Updated Summary of Latest Technology

Metallurgy

  • The Effect of Cooling Rate After Homogenization and Billet Preheating Practice on Extrudability and Section Properties of an Al-Mg-Si Alloy — Part 2: A Microstructural Investigation
  • Improved Properties of Extruded Products by Heat Treatment of AA6082 Alloy Sections
  • The Effect of Homogenizing Heat Treatment Practice on the Productivity of Al-Mg-Si System Alloy
  • Development of Structure, Recrystallization Kinetics and Prediction of Recrystallized Layer Thickness in Some Al-Alloys
  • Texture and Surface Grain Structure in Aluminum Sections
  • Extrusion with Active Friction Forces as an Innovation in Light Alloy Metallurgy
  • Co-Extrusion of Aluminum Laminar Composites From Billets with Mushy and Solid Phases
  • A Test Facility to Enable Study of Post-Extrusion Quenching for Production Distortion Control
  • Fine Powder P/M Extrusion Processing for Aluminum-Matrix Composites: Front Pad Extrusion Method
  • Observations on Production and Limit Diagrams for the Extrusion Process
  • Use of EBSD Technique for Microstructural Characterization of the Deformation Zone in Aluminum Extrusion
  • Flow Stress Parameters During the Extrusion of Aluminum Alloys
  • Future Perspectives on the Development of Alloy Composition and Processing for Extrusions
  • Temperature Distribution in Aluminum Extrusion Billets
  • Deformation Conditions of Steady Shaping of Internal Capillary-Ribbed Surface in Extruding Heat Pipes in Aluminum Alloys
  • Further Developments in the Extrusion of Aluminum-Based Metal Matrix Composites .
  • Constitutive Equations and Flow Stress Characterization Concepts for Aluminum Extrusion

Eqipment Design and Maintenance

  • New Technology in Extrusion Press Design
  • How to Obtain the Most from Your Ageing Ovens
  • The Maintenance of Extrusion Plant: Operating Extrusion Presses for Maximum Efficiency
  • Real-Time Maintenance Package: An Expert System for Automatic Hydraulic Fault Diagnostics Embedded in a Supervisory Computer
  • High-Temperature Textile Products for Aluminum Extrusion Handling Systems
  • A “No-Man” Extrusion Handling System
  • News on 2000’s Press Technology: “NBE” Burp Cycle
  • Improving Fixed Dummy Block Performance
  • The Ultimate Modernization
  • Extrusion Line for Big Profiles

Extrusion Cooling Processes

  • New Technologies for the Cooling and Quenching of Medium-to-Large Sized Aluminum Extrusions
  • Thermal Stretching of Aluminum Extrusions

Modeling

  • Computer Prediction of Extrusion Limit Diagrams
  • Microstructurally Based Modeling Applied to Cold Extrusion of Aluminum

Temperature

  • Noncontact Temperature Measurement of Aluminum: Its Design, Performance and Function on Aluminum Extrusion
  • Influence of Plastic Strain and Strain Rate on Temperature Rise in Aluminum Extrusion

Extrusion FEA

  • Application of the Finite-Element Technique to the Simulation of the Aluminum Extrusion Process
  • Simulation of Tube Extrusion in a Two-Dimensional, Axisymmetric Model . . . . . . .

Publish Only

  • Control Framework and Deformation Modeling of Extrusion Processes: An Upper Bound Approach
  • The Heat Balance During Multiple Press Cycles
  • Extrusion of Some Al-Li-Mg-Zr Alloys
  • Microstructural Evolution During Extrusion of Low Density Al-Alloys Prepared from Rapidly Solidified Powders
  • On the Relationship Between Extrusion Conditions and Fracture Toughness
  • Mathematical Computer-Aided Determination of Heating Processes in Aluminum Logs and Billets During Heating to Extrusion Temperature in Gas-Fired Billet Heaters
  • Extrusion with the Use of Active Friction Forces (EwAFF)

BILLET PROCESS AND EQUIPMENT

  • The Role of Modeling in the Design and Operation of Remelt and Casting Facilities

Modeling/Refractories/Equipment

  • Modeling Casthouse Operating Costs
  • Thermal Performance of Insulating Refractories for Casting Applications
  • Compact Type Remelt Plant with Horizontal DC Casting and Continuous Homogenization

 Burners

  • A User’s Experience with Retrofitting an Aluminum Melting Furnace with Low NOx Regenerative Burners
  • Case History of an Aluminum Melter with Twinbed II (Regenerative) Low NOx Burners

Dross

  • Selection of THE PRESS Dross Processing System and the Results of Two Years of Operation
  • Inert Gas Dross Cooling (IGDC) — The New Standard

Metal Preparation

  • Molten Metal Quality Considerations for Aluminum Extrusion Ingot Product
  • Gains in Degassing System Designs Obtainable with Sialon Immersion Heating Technology
  • The Development and Performance Evaluation of a Dual-Stage Ceramic Foam Filtration System

Safety

  • Summary of Ten Years of Molten Aluminum Incident Reporting
  • Scrap Melting Safety for the Casthouse

Furnace Design

  • Remelt Aluminum Furnaces

Process Control and Technology

  • Augmented Water Exit Geometry for Billet Molds
  • Strategies for the Effective Application of Microbiological Control to Aluminum Casting Cooling Systems
  • Prevention of Cast Cracks in Al-Zn-Mg-Cu Alloy Castings
  • Precipitation of Mg2Si in Al-Mg-Si- Alloys During Cooling from Homogenization Temperature

Billet Processing

  • Performance of Secondary Versus Prime Billet
  • Structural Modifications Occurring During the Homogenization of Some 7XXX Alloys
  • Improved Operating Efficiencies of Log Homogenizing Furnaces
  • Band Saw for Billets: The Future

Water Quality

  • Consistent Water Quality for Aluminum Casting . . . an Important and Attainable Goal

VOLUME II – Brief Contents

  • Die Design and Technology
  • Applications and Product Innovations

DIE DESIGN AND TECHNOLOGY

  • Tribological Evaluation of Surface Treatments for Extrusion Dies

Die Technology

  • Application of Upper Bound Method to Extrusion Die Design
  • Accurate Temperature Measurements Inside the Tool in Hot Working of Metals
  • Metal Flow in Die Channels of Extrusion Investigated by an Experimental Grid Pattern Technique

Computer Design

  • The Computer-Aided Design and Computer-Aided Manufacture of Extrusion Dies
  • A 3D Feature-Based Computer Support Tool for the Design of Aluminum Extrusion Tool Assemblies

Finite Element Analysis

  • Automatic Bearing Length Assignment Using the Medial Axis Transform
  • Simulation of Aluminum Extrusion Based on a Finite Element Method (FEM )
  • Analysis of Metal Flow in Weld Pocket Dies
  • Numerical Simulations in Extrusion Die Design
  • Effect of Blend and Extrusion Parameters on Material Flow

Weld Quality

  • Transverse Weld Defects

Bearings and Metal Flow

  • A Modified Classification System for Metal Flow Adapted to Unlubricated Hot Extrusion of Aluminum and Aluminum Alloys
  • An Experimental and Numerical Investigation of the Thermo-Mechanical Conditions on the Bearing Surface of Extrusion Dies
  • Studies of Dead Metal Zone Formation in Aluminum Extrusion
  • Metal Flow in Two-Hole Extrusion

Bearing Surfaces

  • Interface Mechanisms on the Bearing Surface in Extrusion
  • Housing of Ceramic Die Inserts for Aluminum Extrusion
  • Metal Flow and Temperatures Developed During Direct Extrusion of AA2024
  • Direct Extrusion of AA6060 Through Dies with Coated Bearing Lengths

Die Design Systems

  • System to Calculate Chambers and Feeds to Obtain an Extrusion Die Designed, Manufactured, and Produced with One Single Minimum Bearing. Tests Results and Results as Reported by Licensees. Present Status
  • The Use of a Planning System to Support the Design of Extrusion Dies – Rapid Determination of Bearing Lengths
  • Design of Hollow Dies for Manufacturing Thin-Walled Hollow Sections
  • Analysis of the Deformations that are Active on the Webs of Hollow Dies during the Extrusion Cycle. Analysis Conducted by Finite Elements

Die Treatments

  • Ion Nitriding of H.13 Extrusion Dies Using the Pulsed Plasma Technique
  • The Heat Treatment of Extrusion Tools Using Fluidized Bed
  • A Review of the Surface Modification Techniques for Pre-Heat-Treated H.13 Extrusion Dies and Emerging Technologies
  • Surface Enhancement Technology for Metal Extrusion

Hollow Dies and Special Die Designs

  • Advanced Design and Manufacture of Hollow Dies or Improved Extrusion Speeds
  • Extrusion Welding in Porthole Die Extrusion
  • Determination of Parameters Required for Joining Process in Hollow Dies
  • Convex Dies for Aluminum Extrusion

Coatings/Finite Element Analysis

  • Plasma Sprayed Ceramic Coatings for Extrusion Dies
  • Application of Upper Bound Element Technique (UBET) for Aluminum Extrusion

Publish Only

  • Influence of Die Handling Operations on Performance of Nitrided Aluminum Extrusion Dies
  • An Industry Update on the Use of Abrasive Flow Machining for Exrusion Die Polishing

APPLICATIONS AND PRODUCT INNOVATIONS

  • An Architect’s Perspective on Aluminum

Automotive

  • Designing for Tomorrow’s Customer Needs — An Electric Vehicle Charger
  • Bending of Aluminum Extrusions for Automotive Applications: A Commentary on Practical and Theoretical Aspects
  • Aluminum Spaceframe Technology Applied to the Development of a Low Investment Electric Vehicle Prototype

Alloys/Bridges and Structures/Extrusion Packaging

  • Extrudability and Mechanical Properties of Some 7XXX-Series Alloys
  • Aluminum Alloys for Bridges and Bridge Decks
  • New Rules for Determining the Strength of Extruded Shapes
  • Automatic Packaging and Handling of Aluminum Extrusions-Extruders Needs and Customers Requests

TPM/Innovative Product Development

  • Improving Equipment Effectiveness Through Total Productive Manufacturing
  • How to Use Aluminum Price Volatility When Developing a Product
  • Aluminum Service Centers — Your Opportunity for Profitable Growth
  • Aluminum Extrusion House in Fort Pierce, Florida

Finishing

  • The “Zero Discharge” Anodizing Line
  • Mechanical Etching of Aluminum Sections Prior to Anodizing, Painting or Powder Coating
  • Chrome Free Pretreatment: A Cost Effective Solution to the Elimination of Environmental and Workplace Concerns Surrounding Chromium
  • Novel Siloxane Coatings to Meet Changing Environmental Regulation and High Performance Requirements of Quality Aluminum Extrusions   . . .

Innovative Business Practices

  • Service Centers: A Channel to Quality Oriented Customers!
  • Today’s Users’ Expectations of Extruders: Quality, Service, Partnership
  • Continuous Quality Improvement Attaining ISO-9002 Certification
  • EDI — Why Should I Be Interested?

Welding and Brazing

  • Production of Wide Aluminum Profiles by Solid-State Friction Stir Welding
  • Cost Saving by Aluminum Robotic Welding
  • New Bending Process for Aluminum Alloy Extruded Shape by Pulse YAG Laser Welding
  • Controlled Atmosphere Brazing of Aluminum Automotive Heat Exchangers

Quality

  • Visual Quality Attributes of Aluminum Extrusions

Processing/Training Methods

  • Computer-Aided Design of Industrial Bending Processes for Aluminum Extrusions
  • Fiber Abrasive Finishing Systems for End-Deburring Extruded Aluminum Profiles
  • Aluminum: Different? Yes. Difficult? No. When You Know How

Advanced  Technology

  • New Extrusions for Building Construction Connections
  • Opportunities and Pitfalls to Combine Aluminum Extrusions with High-Pressure Die Castings
  • The Concept of Becoming a User/Extruder
  • Improvement of Surface Hardening for Aluminum Extrusion Products

Conform

  • Development of Conform Technology for the Manufacture of Multi-Port Tube
  • Simulation and Analysis of Deformation in Conform Extrusion

Miscellaneous

  • Profiles of Change in India
  • Secondary Aluminum MACT Development

Product Liability

  • The Role of Sales in Product Liability Loss Prevention

Publish Only

  • Managing the Human Side of a Press Installation or Modernization Project