Proceedings of the 9th Aluminum Extrusion Technology Seminar (2008)

The Ninth International Aluminum Extrusion Technology Seminar — ET’08

May 13-16, 2008
Orlando, Florida, USA

ET ’08 Proceedings — Set (Book & CD)

ET ’08 INDIVIDUAL PAPERS

VOLUME I — Brief Contents

EXTRUSION EQUIPMENT

  • Non-Destructive Examination Components

Measurement & Diagnostics

  • Unique Tool Matching System
  • Diagnostics and Experiences on Extrusion Press Tooling
  • New Measurement System for Quality Control

Press

  • Seven Steps for Selecting An Extrusion Press
  • Comprehensive Extrusion Automation for Iso-thermal Iso-speed Extrusion with Guaranteed Cooling Rate
  • Innovative Tube Extrusion Plant for Aluminum Alloys
  • Clean Oil: The Lifeblood of the Modern Extrusion Press System
  • Second-Generation Combination Quenches: Improving the Theory and Practice
  • Profile Aging Systems: Traditional, Semi-Continuous, Continuous—Differences, Advantages, Costs

Control

  • Automatic Closed-Loop Control Comes of Age for Aluminum Extrusion
  • Process Controlled Containers – Smart Containers
  • Water Hydraulic Press Control

Container & Tooling

  • Extrusion Container Technology from Yesterday until Tommorrow
  • Performance Enhancement of Tool Lube Systems
  • Automated Die-Polishing Update
  • Abrasive Flow Machining

Billet/Log Heating/Handling

  • New Conveying System in Rapid Gas-Fired Heaters in Combination with Hot Log Shear or Log Welder and Hot Log Saw
  • Operational Experience of a Highly Efficient Induction Billet Heater: Improving Energy Efficiency with Superconductivity
  • Building a 200 kW Rotating Billet Superconducting Induction Heater

Sawing

  • Hot Billet Saw: a Real Innovation in Handling Equipment
  • Sawing Hot Billets at the Extrusion Press

EXTRUSION/DIE, PRACTICAL

  • Scrap Allocation
  • Extrusion Surface Effects Resulting From Billet Surface Inflow

Recovery Improvement

Extrusion Process

  • Implications and Influence of Complex Extrusions and Non-Standard Shapes on the Extrusion Press Productivity
  • Process of Achieving Extrusion Excellence
  • Boron Nitride – Solutions for Aluminum Extrusion
  • Simulation-Aided Extrusion: An Efficient Optimization Strategy

Tooling Performance

  • The Use of Gaseous Nitrogen to Improve the Surface Finish of Dilute 6xxx Extrusions
  • Butterfly Dies – Increase Extrusion Speed through Innovative Porthole Die Design
  • Metal Flow in Extrusion with Different Orifices
  • Gas Nitriding Versus Ferritic Nitrocarburizing in Surface Hardening of Extrusion Dies
  • The Die Does Not Make the Extrusion
  • Die Performance Optimization through Understanding of the Surface Features of Fatigue Fractures
  • The Case-Based System for Aluminum Extrusion Die Design in a Context of Integrated Design
  • Extended Die Life and Consistent Weight Per Foot Using BC-115 Inserted Tooling
  • Extrusion Die Specification:  How to Obtain Repeatable Performance

Quench and Temper

  • Progressive Quenching: A New Approach to Distortion Control
  • The Development of a High Performance Product Created Through the Combination of Metallurgical Technology, Process Control and Lean Manufacturing
  • Quench Sensitivity Test Method for Aluminum Extrusion Alloys
  • Two-Step Aging Behaviors of Al-Mg-Si Alloy Extrusions

Hollow Profiles and Heat Exchanger Profiles

  • Static and Dynamic Mechanical Properties of Longitudinal Weld Seams in Industrial AA6060, AA6082 and AA7020 Aluminium Extrusions
  • Quality Issues of Hollow Extrusions for Aerospace Applications
  • Seam Welds Modeling and Mechanical Properties Prediction in the Extrusion of AA6082 Alloy
  • Experimental Study of Longitudinal Weld-Seam Properties in Tubular AA6060 and AA6082 Extrusions
  • Seam Welds Quality in AA6060 Alloy
  • Development of Latest Heat Exchanger Tube Technology
  • Optimizing AA3003 for Extrudability and Grain Size Control

MANAGEMENT ISSUES

  • Continuous Extrusion Optimization System

Operations Management

  • A Two-Decade Case Study – How Modeling Drove Exceptional Results
  • Implementation of Six Sigma Methodology in the Extrusion Die Shop

Quality Management

Market

  • Increasing the Use of Extrusions for Electrical Applications Technical and Economic Considerations
  • The Evolving Heat Exchanger Market for 3xxx Series Extrusions
  • Upcoming Structural Design Rule Changes Impacting Aluminum Extrusions

Globalization

  • Development of Recycling-Friendly Aluminum Alloys for Extruded Products
  • The Globalization Trap of the Aluminum Extrusion Industry
  • Indian Aluminum Extrusion Industry – Challenges and Opportunities
  • The Role and Use of Aluminum in “Green” Architecture

VOLUME II — Brief Contents

BILLET PROCESS and EQUIPMENT

  • Al-Mg-Si Alloys with Improved Crush Properties

Alloy Development

  • The Future of 6xxx Medium Strength Structural Applications
  • New Generation of Matte Alloys from Alcan

Metal Quality

  • Metallurgical Quality of Aluar Billets, Ten Years of Increasing Quality
  • Cl2-Free Aluminium Processing Technologies
  • Degassing Technology: a Review of Design and Operational Considerations for Effective Removal of Hydrogen In Molten Aluminum
  • Improved Hydrogen Measurement In Molten Aluminum and Aluminum Alloys

Metallurgy

  • Effect of Alloy Chemistry and Process Parameters on the Extrudability and Recrystallization Resistance of 6082 Aluminum Alloy
  • The Effect of Scandium and Zirconium Additions on Aluminum Extrusion and Post-Braze Grain Structure
  • Standardization in Metal Analysis — No Longer an Option

Furnaces

  • Electromagnetic Stirring for Aluminum Furnaces
  • O2 Enhanced Combustion for Aluminum Melting Furnaces
  • The Art of Dross Management- Maximizing Dross Values and Minimizing Dross Generation
  • Dross Reduction In the Aluminum Casthouse: General Considerations and Practices

Casting Homogenization

  • Understanding Key Factors to Improve Billet Surface Quality and Casting Mold Life
  • Advanced 6xxx Alloys – Challenges in Casting and Extrusion Process
  • Measurements and Modeling of Precipitation and Dissolution during Cooling and Preheating of Extrusion Billets

EXTRUSION/DIE, THEORETICAL

  • Control of Asymetric Recrystallization in Single and Multi-Hole Die Extrusion

Microstructure

  • Influence of Geometric Dynamic Recrystallization in the Dead Metal Zone on Peripheral Coarse Grain Defect Formation in Indirect Extrusion
  • Prediction and Control of Subgrain Size in the Hot Extrusion of Aluminum Alloys with Feeder Plates
  • Innovative Methodologies to Increase Productivity by Simulating Development of Structure During Extrusion and Solution Soaking
  • Grain Size Prediction in AA6060 Profile Extrusion
  • A Review of Recrystallization Mechanisms as Related to Complex Forgings Produced from Extruded 6061 Forging Stock

Modeling and Simulation

  • Simulation and Experimental Investigations on Composite Extruded Processes
  • Thermomechanical Simulation of Continuous Extrusion
  • Application of Qform Program for Improvement of the Die Design and Profile Extrusion Technology
  • 3-D Numerical Simulation of Direct Aluminum Extrusion and Die Deformation
  • Flow Front Tracking Simulations in Aluminum Extrusion Dies Using an Eulerian Description and a Comparison with Experiments
  • Advanced Numerical Techniques to Simulate Extrusion
  • Process Engineering Modeling a Ticket to Higher Efficiency In Aluminum Extrusion

Neural Networks

  • Analysis of Mechanical Properties of 2xxx T3 and T8 Aluminum Extruded Rods by Means of Neural Networks
  • Use of Adaptive Neural Networks (ANN) In the Aluminum Extrusion Process Control

Dies and Modeling

  • Extrusion Simulation as the Way to “Close the Loop” In Die-Design
  • Indirect Extrusion of Rapidly Solidified AI-Base Alloy Powder/ Flakes and Deformation Behavior of the Extrudate
  • Die Design and Manufacturability Formalization Using the Medial Axis Transform
  • Biomechanics In Extrusion Dies! Finding a Proper Web Cross-Section in Porthole Dies Regarding a Fish Body
  • Lifetime Comparison of Different Hot Work Tool Steels for Extrusion Tools in Aluminium Extrusion

Metal Flow, Weld Seam, Modeling

  • Solid–State Bonding in Longitudinal Weld Seam Formation
  • Extrusion Benchmark 2007 – Benchmark Experiments: Study on Material Flow Extrusion of a Flat Die

VALUE-ADDED PROCESSES

  • Mechanisms of Streaking on Anodized 6xxx Series Extrusions

Customers

  • Hybrid Nanostructure of the Anodic Oxide as an Alternative Finish for Extrusions:A Case Study
  • Friction Stir Welding of Aluminium Alloy Extrusion Panels for NZ Navy Inshore Patrol Vessels Building
  • Decoral System: for the Decoration of Extruded Aluminum Profiles
  • Thermal-Efficient Products Through Computer Simulation Software
  • Filiform Corrosion and Results of 10 Years Natural Weathering

Metal Forming

  • Retrogression Heat Treatment as a Means of Improving Formability of Aluminum Extrusions
  • Flexible Extrusion of 3D-Curved Profiles for Structural Components
  • A New Advanced Profile-Shaping Technique for Design and Manufacturing of Automotive Components

Anodizing

  • Innovative Anodizing and Coating Technologies for Processes and Plants of the Future
  • Chemical Depth Profiling of Anodized Extrusion Surfaces Using rf-GD-OES

Paint

  • A Safer Alternative to Chromate Passivation for Aluminum Pretreatment
  • Choosing the Best Coating Solution for Aluminum Extrusions
  • Comparative Study of Electrostatic Applicators for Vertical Powder Paint System. Traditional Multi-Gun Applicators Versus the Single Over Flow Bed (O.F.B.) Disk System
  • Automatic & Self-Cleaning Booth for Vertical Powder Coating Lines
  • In-Line Paint Stripping of Hooks
  • A Non-HAP (Hazardous Air Pollutant) Coating for Extruded Aluminum

Fabrications

  • Aluminum Extrusion Fabrication Solutions for the Automotive & Transportation Markets
  • Codes and Standards for Aluminum Welding

Packaging

  • Process Control and Data Acquisition and Its Direct Impact on Plant Wide Operational Excellence
  • Managing Your Product from Your Dock to the Customer’s Dock
  • New Solutions for Packaging Extrusions

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