Proceedings of the 8th Aluminum Extrusion Technology Seminar (2004)

May 18-21, 2004, Orlando, Florida

ET ’04 Proceedings 

Volume I – Brief Contents

  • Extrusion Process
  • Extrusion Equipment
  • Management Issues

 EXTRUSION PROCESS

  • Isothermal Extrusion of Aluminum Alloys
  • Control of Grain Structure in Al-Mg-Si Extrusions

Metal Flow

  • Upset
  • Measurement of Pressure and Friction on the Container Surface During Aluminum Hot Extrusion
  • Study on Metal Flow in Extruded Billet
  • Metal Flow in Billets of Thin-Walled Extrudates
  • An Investigation of Size Effects in Miniature Hot Extrusion

Peripheral Coarse Grain

  • Prediction of Static Recrystallization During Shaped Extrusion
  • Application of FEM to Modeling of Multi-Hole Die Extrusion
  • Analysis of Peripheral Coarse Grain Recrystallization in 6xxx Aluminum Alloy Extrusion
  • Effects of Extrusion Parameters on Coarse Grain Surface Layer in 6xxx-Series Extrusions
  • Microstructural Gradients Near the Surface of Large 6xxx Aluminum Extrudates
  • Thermomechanical Modeling of Coarse Grain Formation of Al-Mg-Si Alloy During Extrusion
  • Prediction of Flow Stress and Recrystallization by the Finite Element Method During the Hot Extrusion of Aluminum Alloys
  • Prediction of Extruded Microstructures Using Experimental and Numerical Modeling Techniques

Metallurgy/Measurement

  • A Methodology for Quantitative Three-Dimensional Comparison of Experimental and Computer Simulated Microstructural Textures of 6xxx Aluminum Alloys
  • Thermomechanical Effects of the Presence of Magnesium–Silicide in 6xxx Alloys at Extrusion Temperatures
  • The Process of Gaining Extrusion Speed in 6xxx-Series Alloy
  • The Role of Metallography in the Characterization of Aluminum Extrusion Defects and Failures

Temperature Measurement

  • Thermal Management Practices for Aluminum Extrusion
  • Integrated Extrusion Thermometry and the Measurement of Quench Rate
  • Real Temperature Parameters for Isothermal Extrusion

Extrusion Process

  • HyperXtrude/Process – Extrusion Process Optimization Software
  • Effect of Section Thickness on Magnitude of Shape Variations During Cooling of Flat, Extruded Sections
  • Studies of the Effects of Flow Imbalance on Shape Variations in Aluminum Extrusion by use of Lagrangian FEM Software
  • Evaluation of the Applicability of a Thermomechanical Model to Industrial Extrusion Experiments of AA6063
  • A Manufacturing Flow-Path Simulation of the Microstructure Evolution of 6260 Aluminum Alloy During Extrusion Processing
  • Temperature Changes and Their Effect on Deformation During Extrusion Using FEM
  • Results of an Investigation of Forward and Backward Extrusion with FEM Program QForm

EXTRUSION EQUIPMENT

  • The Analysis of a Fatigue Failure of a Large Indirect Aluminum Extrusion Press Container Mantle

Container

  • Tool Steel and Design of Modern Containers for Extrusion of Light Metal
  • New Developments in the Design and Production of Container Assemblies
  • Thermal Control of the Extrusion Press Container

Presses

  • Catastrophic Failure: A 48-Hour Remedy
  • Building a “Green Field” Extrusion Plant in the 21st Century
  • Front-Loading Technology with Tandem Cylinder Design for High Precision Extrusions
  • Special Purpose Extrusion Press for the Production of Curved Profile
  • The Extrusion Press Line for 2024: A Forecast
  • The Maintenance of Extrusion Presses With Specific Reference to Press Tooling

Controls

  • Upgrading Extrusion Presses with Variable Frequency Drives
  • Practical Non-Contact Temperature Measurement for Gas-Fired Billet Heating Furnaces
  • Automation System for Production Optimization in Aluminum Extruder Plants, Based on Temperature Measurement and Control

Induction/Billet Temperature

  • Process Control Improvements for Single Billet Induction Heaters
  • Induction Heating of Aluminum Billets Using Superconductors
  • Progress in Single-Billet Induction Heaters for Light-Metal Extrusions Works
  • Improvements in Modern Heating Techniques for the Extruder
  • Influence of Log and Billet Temperature Gradients on the Productivity of Extrusion Plants – Theoretical Considerations and Practical Results

Quench

  • Advantages of a “Special Nozzles” Cooling Tunnel
  • High Performance Quenching: Maximum Performance in the Minimum Space
  • A New Horizontal Plant Concept for the T6 Treatment of Hard Alloy Extrusions

Handling

  • Flying Cut Puller Without Hand-Off
  • Technical Textiles for Extrusion Handling Systems: Introducing High Tech While Avoiding Basic Mistakes
  • Innovative F.T.S. Three Puller – Automatic Stretcher System

Age Ovens

  • Continuous Aging Oven for Extruded Profiles in Aluminum Extrusion Plants
  • “Moby Dick” Innovative Continuous Aging Oven for Extruded Profiles

MANAGEMENT ISSUES

  • The Effects of Globalization on the Aluminum Extrusion Industry

Globalization

  • Business Opportunities for Aluminum Extrusions in China
  • Aluminum Profile Industry in China
  • High Quality Extrusions for Railway and Urban Transit Applications in China
  • Aluminum Extrusion Industry in India – Challenges & Opportunities
  • Extrusion Equipment Upgrades for Maintaining Leadership Status in India
  • Aluminum Industry Standards for Extrusions

Safety and Education

  • Extrusion Hazards and Risk Reduction
  • The Aluminum Industry.s Efforts to Prevent Molten Metal Explosions
  • Practical Application of the Future European Extrusion Safety Standard EN 14656 in an Existing Plant near Barcelona
  • Bringing Technical Materials Engineering and Aluminum Information to the K-12 Community

Operation Management

  • Managing the Performance of Extrusion Plant
  • Process and Quality Improvements by Implementation of ISO/TS 16949 in Extrusion Plants
  • The Nine Principles for Best-in-Class Quality
  • Die Correction?
  • Using the Feed-Forward Concept to Integrate and Optimize the Extrusion Process, Die Design, and Management Process
  • Technical Solutions for the Aluminum Extrusion Industry
  • Meeting Today.s Market Challenges Through Strategic Equipment Investments

Volume II – Brief Contents

  • Billet Process and Equipment
  • Die Design and Technology
  • Value-Added ProcessesES

BILLET PROCESS AND EQUIPMENT

  • New Technology – Improving Billet Casting and Extrusion Performance

Billet Casting

  • Advantages of Vertical Bonded Particle Filter Technology in Extrusion Billet Casting
  • The Ultimate Extrusion Scrap Remelt and Casting System

Metallurgy

  • Extrudability and Mechanical Properties of Alcan’s High Performance Al-Mg-Si Alloy
  • Predictive Metallographic Assessment of Extrudability and Comparative Testing of 6xxx Aluminum Alloy Billets
  • Performance of 6xxx Series Alloys Designed for Improved Extrudability and Strength

Homogenization

  • A Model of the β-AlFeSi to α-Al(FeMn)Si Transformation During Homogenization in 6xxx Alloys
  • A Modern View of the Thermodynamics and Kinetics of the Magnesium-Silicide

Billet Processing

  • Use of Boron Nitride Coatings with Aluminum Casting Technology
  • Almech: A Computer Program for Alloy Selection and Extrusion Process Improvement
  • Features of Extrusion of Al and Mg Alloys for Production of Billets with Improved Strength, Plastic and Technological Properties

Molten Metal Treatment

  • The Pechiney Jetcleaner – New Equipment Technology for “In-Line” Treatment of Molten Aluminum Alloys
  • Techniques for Removing Sodium from Molten Aluminum
  • Benefits with Electromagnetic Pumping Technology in Extrusion Alloy Melting Furnaces
  • The Casthouse Safety Program

Equipment

  • Traveling Billet Homogenizing Furnace
  • Compact Type Remelt Plant for Contaminated Scrap Using Latest Melting Technology

DIE DESIGN AND TECHNOLOGY

  • Effect of the Convex Die Geometry on the Process Parameters During Extrusion

Finite Element Method

  • Finite Element Method (FEM) Investigations for Practical Extrusion Issues — Extrusion Process for Complex 3-D Geometries; Pocket Die Designs; Transverse Weld Phenomenon
  • Analysis and Design Optimization of Aluminum Extrusion Dies
  • Prediction of Material Flow Pattern in the Hot Extrusion of Aluminum Alloys by the Finite Element Method
  • Microstructural Evaluation of Convex Die Extrudates
  • Experimental and Numerical Investigations of Aluminum Extrusion Through Pocket Dies
  • Numerical Simulation of Behavior of Weld-Pocket Dies during Extrusion of Thin-Walled Solid Sections
  • Consideration of Surface Formation and Cracking and Control by Isothermal Extrusion; Simulation of These Factors by the Finite Element Method (FEM)
  • Evaluation of a New Finite Element Method (FEM) Criterion for Seam Welds Quality Prediction in Aluminum Extruded Profiles
  • 3-D Finite Element Method (FEM) Simulation System for Optimization of Profile Extrusion
  • Integration of 3-D Finite Element Flow Modeling in Extrusion Tool Conception and Fabrication

Practical Design

  • Die Design – The Next Generation
  • The Effect of Die Type and Die Design on Heat Generation and Productivity when Extruding AlMgSi Alloys
  • Integrated Computer-Aided Extrusion Hollow Die Design Methodology
  • Introducing Simulation Technology to Die Design

Technology in Practice

  • Use of Tribology to Improve Performance and Quality in Aluminum Extrusion
  • The Fixed Dummy Block
  • Die Heating in Production
  • The Single-Cell Die Oven
  • Automated Polishing and Cleaning of Aluminum Extrusion Dies
  • Study of Cost Savings in Die Trial and Die Correction With New Inspection Technologies
  • Software Application for the Management of Profiles, Backers, and Bolsters
  • Weight Per Meter Control Through Accurate Die Aperture Size

Surface Treatment and Materials

  • Deposition of Hard Films on Hot-Work-Steel Dies for Aluminum Extrusion
  • CVD Coating Technology for Increased Lifetime of Aluminum Extrusion Dies
  • Nitriding of Extrusion Dies: Problems and Solutions
  • Extrud-ALTM — An Alternative Approach to Nitrogen Die Cooling
  • Modern Extrusion Die Hardening and Nitriding
  • Ni3Al-Based Composites as Alternative Die Materials for the Extrusion of Hard Aluminum Alloys
  • Fundamentals of Advanced Aluminum Extrusion Processes

VALUE-ADDED PROCESSES

  • Wider Extrusions at Lower Cost by Friction Stir Welding

Welding

  • Friction Stir Welding Tools and Techniques for Welding Aluminum Extrusions
  • Promoting the Use of Aluminum Extrusions within the Welding Fabrication Industries

Extrusion

  • Changes to Extrusion Application Design in the Aluminum Design Manual 2005
  • Manufacturing Process of Curved Extrusions for Aluminum
  • Production of High-Curved Extruded Profiles Directly During the Extrusion Process
  • Effect of Stretching on Extrusions for Residual Stress and Distortion
  • Industrial Experience of Caustic Soda Recovery Integrated with Automatic Die Cleaning
  • Enhanced Tool Lubrication Systems

Fabrication

  • Manufacture of Continuously Reinforced Profiles Using Standard 6060 Billets
  • Improving Thermal Performance in Structural Fenestration Products
  • New Advanced Automation in Extrusion Working and Assembly
  • Design and Fabrication of Aluminum Automobiles
  • A CNC Machining Center for Processing Aluminum Profiles for the Train Industry

Anodizing

  • Outdoor Exposure Performance of Anodized Finishes
  • A New Economic Two-Step Coloring Process for Bronze and “Stainless Steel” Colors
  • Anodized Architectural Aluminum Combined with an Organic Seal

Paint-Based Finishes

  • Chrome-Free Pretreatment: A Cost-Effective Solution to the Elimination of
  • Environmental and Workplace Concerns Surrounding Chromium
  • Decoral System: for the Decoration of Extruded Aluminum Profiles
  • Process Control and Data Acquisition for Pretreatment Washer Systems Utilizing Computerized Graphics