Proceedings of the 7th Aluminum Extrusion Technology Seminar (2000)

May 16 — 19, 2000

Chicago,Illinois USA

VOLUME I – Brief Contents

  • Extrusion Process
  • Extrusion Equipment

 EXTRUSION PROCESS

Process

  • Simulation of Flow of the Billet Surface into the Extruded Product
  • Optimizing Extrusion through Effective Experimentation and Analysis
  • Effect of Preheating Practices for Unhomogenized 6063 Alloy Billet on Billet Microstructure and Extruded Properties
  • Extrusion Defects – Helping the Customer to Solve Them!

Quenching

  • Quench Sensitivity of 6063 and 6082 Aluminum Alloys
  • Taper Quenching, A Case Study
  • Smart Quenching

Flow and Modeling

  • Numerical Simulation of the Extrusion of Complex (Hollow) Profiles
  • An Evolution- and Biology-Based Approach to the Optimization of the Extrusion Process
  • Modeling Mg2Si Dissolution in an AA6063 Alloy During Preheating to the Extrusion Temperature
  • 3D FEM Simulation of Thermal and Mechanical Events Occurring During Extrusion Through a Channel-Shaped Die
  • Semi-Empirical Modeling of Multi-Hole Extrusion on a 5000-Ton Indirect Extrusion Press
  • Material Flow and Prediction of Extrusion Pressure when Extruding Through Bridge Dies Using FEM
  • FE-Analysis of Inward Flow of Surface Materials at the Back End of Billet During Al–Extrusion
  • Physical and Numerical Modeling of Billet Upsetting
  • New Hollow Extrusion of High Strength Al-Mg-Si-Cu Alloy
  • Multipurpose Friction-Assisted Indirect Extrusion (FAIE) Technology
  • On the Mechanics of Friction During the Extrusion Process
  • Theoretical and Experimental Analysis of Seam Weld Formation in Hot Extrusion of Aluminum Alloys
  • Simulation of the Effect of Tooling and Billet Condition on Bulk and Surface Metal Flow During Extrusion

Metallurgy

  • Effect of Die Design on Microstructure of Extruded Aluminum
  • Crystallographic Analysis of Deformation Zone in 6xxx Aluminum Alloys
  • Effect of Large Plastic Strains Accumulation on Aluminum Structure and Properties
  • A Review of New Approaches and Technologies in Extrusion Welds Related to the Background of Existing Knowledge
  • The Effect of Extrusion Conditions on the Surface Properties of AlMgSi (6063) Hollow Sections
  • A New Metallographic Technique to Reveal Grain Structure in 6000 Aluminum Alloys
  • Temperature-Speed Parameters in Extrusion of Thin-Walled Sections from Aluminum Alloys

Hard Alloy

  • Extrusion of 2xxx & 7xxx Alloys
  • Optimal Conditions for Extrusion Processes of Aluminum Alloys in Mushy State and Composites in Mushy-Solid State
  • On the Relationship between Extrusion Conditions, Mechanical Properties, and Surface Acceptability in Some Hard Aluminum Alloys
  • Sources of Blister in 7075 Thin Gage Extrusion in Fabrication

Processing Special Materials

  • Extrusion of Shapes and Tubes in Dissimilar Alloys
  • Extrusion of High-Performance Shapes out of Hard Deformable Aluminum Alloys by Friction-Assisted Extrusion Method
  • Extrusion of High-Hot Strength Aluminum Alloys Produced by Powder Metallurgy

Quality Control BIAS

  • Minimal Attainable Wall Thickness in Aluminum Extruded Sections
  • Effect of Chemistry, Extrusion Speed and Temperature, Die Design on Recrystallized Layer Thickness in Extruded Aluminum Alloy 6061
  • Thermal Cycle Simulation of 6xxx Aluminum Alloy Extrusion

EXTRUSION EQUIPMENT

  • Implementation of Temperature Measurement and Control in Aluminum Extruders
  • Intensive Cooling of Light Metal Alloy Extrusions by Air and Water
  • High-Performance Cooling for Large Aluminum Sections – Industrial Application of a Compact Combined Air-Water In-Line Quench
  • Tool Steels and Design of Modern Light Metal Extrusion Containers
  • Managing Extrusion Plant Maintenance

Press

  • Manufacture of a Four-Part Container for a 13,000 T Extrusion Press
  • Objective Examination of Converting a Long Stroke Aluminum Extrusion Press to a Short Stroke Type
  • Extrusion Press Total Control System
  • Presses Operating with Tandem-Mounted Cylinders
  • Extrusion Press Alignment with Modern Technology
  • A Low Energy, Reliable, Electro–Hydraulic System for Extrusion Presses

Post Press

  • Semi–Continuous Aging Oven
  • New Aging Furnace Designed for Improved Quality and Increased Production
  • Power Consumption Control: A New Temperature Control System for Aging Furnaces and other Chamber Furnaces
  • Improved Layout and Handling Downstream of the Extrusion Line

Conform

  • Practical Experience with Castex
  • Extrusion Zone Gap Measurement and Control of the ConformTM Process
  • Plane Strain and Three-Dimensional Coupled Thermomechanical Simulation of the Conform Process
  • The Structure and Development of a Computer Model to Simulate the Conform Process
  • Axisymmetric Modeling of Aluminum Extrusion Using an Expansion Chamber

Temperature Control

  • Advanced Process Temperature Monitoring and Control System (APTMC System)
  • Closed-Loop Isothermal Extrusion
  • Temperature Controlled Container Heating-Cooling Systems
  • Continuous Control of Thermodynamic Temperature in Extrusion, Rolling, and Forging of Aluminum Alloys
  • Complete Extrusion Press Control Thermometry — A Reality at Last

Billet Heating

  • Extrusion Furnace Technology
  • A Novel Gas-Fired Plant for Fast Heating of Light Metal Billets using High Convection Technology

Profile Measurement

  • The Application of Geometric Acquisition Devices (GAD) for
  • Process Control in the Aluminum Extrusion Industry
  • Using Digital Scanning Techniques for Inspection of Extruded Profiles

VOLUME II – Brief Contents

  • Billet Process and Equipment
  • Die Design and Technology
  • Value Added
  • Management Issues

 BILLET PROCESS AND EQUIPMENT

  • Comparison of the Extrusion Performance and Product Characteristics of Three Structural Extrusion Alloys: AA6061, AA6082, and AA6005A
  • Optimized 6xxx Alloy Billet Performance: A Structured Approach

Metallurgy

  • The Mechanism of Pick-Up Formation on 6063 Aluminum Alloy Extrusions
  • The Control of Precipitation in the Billet for Higher Extrudability of Al-Zn-Mg-Cu Alloys

Metal Treatment and Alloying

  • Rigorous Metallographic Technique for the Examination of Cast and Homogenized 6xxx Log Cross Sections
  • Procias: The Application of Experimental Design Techniques to Optimize the Quality of an Aluminum 6005 Alloy Melt
  • Dissolution of Iron in Aluminum Melt
  • Recent Experience with the Alcan Compact Degasser in Billet and Continuous Casting

Casting/Homogenization

  • An Update on the Aluminum Association’s Molten Metal Safety Program
  • Quantitative Analysis of the Homogenizing Heat Treatment by Means of Al-Fe-Si Particle Analysis and the Effect on Productivity
  • Cooling Water Circulation Core for Casting Hollow Ingots
  • An Overview of Aluminum D.C. Billet Casting

Homogenization

  • Effect of Intermetallic Compound Distribution on Extrusion Surface in 6061 Alloy
  • Effect of Homogenization Cooling Rate and Microstructural Features of Al-Mg-Si Billets on Extrudability and Section Properties in the T5 Temper
  • Continuous Homogenizing of 6xxx Alloy Aluminum Extrusion Billets at Alcoa–Intalco Works
  • An Improved Load Car Design for Log Homogenizing

Furnaces

  • Combustion System Design Impact on Stack Emissions–Comparison and Evaluation
  • Recent Trends in Billet Casthouse Furnace and Casting Equipment
  • New Melt Technology for Aluminum Recycling
  • Meeting Emission Standards While Maintaining Product Quality and Production Throughput

DIE DESIGN AND TECHNOLOGY

  • FEM Simulations of Aluminum Extrusion using an Elasto-Viscoplastic Material Model
  • Modeling of Metal Flow for Bearing Design

Modeling

  • Case Studies on Control of Metal Flow in Pre-Chamber Dies
  • Computer-Based Design of Extrusion Tools
  • Application of FEM Modeling to Simulate Metal Flow Through Porthole Dies
  • Numerical Modeling of Three-Dimensional Aluminum Flow in Extrusion Dies
  • FEM Simulations of the Material Flow in the Bearing Area of the Aluminum Extrusion Process
  • Improving Flow in Soft-Core Bimaterial Billets
  • 3-D Modeling Strength of an Industrial Porthole Die
  • Layered Extrusion Dies – Is there a Need for Rapid Tooling?
  • Development of a 3-D Die Design Tool for Aluminum Extrusion

Design

  • New Process of Manufacturing of Stepped Extrusion with Special Die Set Design
  • Extrusion Die Technology–Meeting the Demand
  • Innovative Extrusion Die with Two-Stage Mandrel for Close Tolerance Hollow Shapes
  • The Metallurgy of the Extrusion Die
  • Weld Integrity on a Die

Die Operations

  • Protect Your Press Tools
  • The Contemporary Fixed Dummy Block: Its Design, Operation, and Maintenance for Maximum Productivity
  • Integrated Die Management System–Key to Economical Efficiency of an Extrusion Plant
  • Improving Extrusion Performance and Quality by Utilizing Die-Splitting and Die-Polishing Systems in the Die Shop

Treatment

  • How PVD Coatings can Increase Life and Improve Die Performance in Aluminum Extrusion
  • The Development and Application of a New, Low-Temperature Surface Hardening Process for Extrusion Tools
  • Optimization of Nitriding Parameters for Extrusion Dies, Evaluated in an Extrusion Simulation Test

VALUE ADDED

A Low-Cost Method of Manufacturing Internal Combustion Engines using Extruded Aluminum  

Finishing

  • Defect Analysis in Anodizing
  • New Finishes for Extrusions: Multicolour Electrolytic Colors for Anodized Aluminum and Their Latest Developments
  • The Lightfastness of Anodized and Dyed Aluminum
  • Pretreatment Processes to Prevent Filiform Corrosion on Painted Extrusions
  • The Effect of Excess Silicon on the Brightening and Anodizing Response of AA6463 Extrusions
  • New Non-Chrome Conversion Coating for Aluminum

Fabricating

  • Extrusion Pretreatments: Alternatives in Cleaning and Conversion Coating
  • Nylon Abrasive Filament (NAF) Brushes – Compliant Tools for Deburring and Finishing Aluminum Extrusions
  • Direct Rounding of Profiles During Extrusion

Marketing and Management

  • Why Go for Aluminum Extrusions?
  • Development of Value Added Extruded Products in the Rail, Shipbuilding and Electrical Markets, Supported by Finite Element Analysis (FEM)
  • Aluma-Strut – The New Shape of Framing

Process Control

  • Considerations for Total Pollution Control: Energy Conservation and Process Control Utilizing Covered Tanks
  • Process Control and Data Acquisition for Pretreatment Washer Systems Utilizing Computerized Graphics
  • Product Development Via Process Control and Complete Integration with Customer

Design and Fabrication

  • Structural Design of Aluminum Extrusions with ADS Software
  • The What, Where, and How of Friction Stir Welding
  • Friction Technology for the Aluminum Industries
  • Increasing Packing Department Productivity and Quality
  • Technological Breakthroughs: New Fabrication/Processing Technologies for Aluminum Extrusions Long Desired by the Markets
  • Aluminum Extrusion and Hydroforming: A Convergence of Technology

Publish Only

  • Microplasmic Aluminum Coating

MANAGEMENT ISSUES

  • Lead Time Reduction Strategies for Value-Added Extrusions
  • Improving the Performance of an Aluminum Extrusion Business
  • Project Management: Introducing High Tech While Avoiding Basic Mistakes
  • Evaluating the Performance of New Extrusion Technologies
  • Incorporating Elements of Aluminum Extrusion Practice into an Undergraduate Engineering Curriculum
  • Extrusion Technology Guide
  • Time, Temperature, and Training in Aluminum Extrusion
  • The Methodology of an Integrated Computer-Aided Extrusion Process Simulation, Die Design/Manufacturing, and Management Planning System
  • The Functionality and System Performance of EXTRUSOFT®
  • The Extrusion Ratio – How to Best Utilize it to Improve Number-of-Ports Decision
  • Reshaping of the Indian Aluminum Extrusion Industry – Challenges and Opportunities