• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09b
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• pp.718-719
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• 2006

Two different commercial aluminium powder grades have been densified by direct hot extrusion. The extrusion temperature was $425^{\circ}C$, with an extrusion ratio of 1:16. Prior to extrusion, some green compacts were pre-sintered ($500^{\circ}C$). The evolution of the extrusion load during the process and the hardness of the final products have been investigated. Additionally, microstructural characterization by X-ray diffraction (XRD), Scanning Electron Microscopy (SEM) and Electron Backscattered Diffraction (EBSD) was carried out. The obtained results evidence grain refinement. Additionally, inter-metallic precipitation, dynamic recovery and geometric dynamic recrystallization take place depending on some process variables, powder composition, heat treatment, strain $\ldots$

• Transactions of Materials Processing
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• v.19 no.5
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• pp.283-289
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• 2010

Extrusion process in the bulk material for fabrication of miniature helical gears has problems such as a high forming load and short tool life because the cross-section is complex and asymmetry. To overcome these problems, in this study, miniature helical gears were fabricated by Zn-22Al powder hot extrusion. The included die angle for minimum extrusion load and improving die filling was determined by FE-simulation. The Zn-22Al spheroidal powder produced by gasatomization were compacted and sintered for extrusion experiment. The dimension of helical-gear is 0.3mm in module, 3.35mm in pitch diameter, $15^{\circ}$ in helix angle and the number of teeth is 12. All of the extrusion experiments were performed with internal helical gear die which was machined by precision electric discharge machining using the electrode. The experiment was conducted at $190^{\circ}C$ to $310^{\circ}C$ to obtain extrusive and mechanical properties. The extruded helical gears were analyzed through extrusion load, Vickers hardness and SEM images for each extrusion temperature. The powder hot extrusion process was successfully applied to fabricate a miniature helical gear.

• Journal of Korea Foundry Society
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• v.11 no.4
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• pp.293-302
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• 1991

Aluminum alloy matrix composites reinforced with various amounts of $Al_2O_3$ short fibers have been produced by a combined technique of rheo-compocasting and hot extrusion. Distribution of fibers in the composites fabricated by rheo-compocasting was relatively uniform. A good degree of uniaxial fiber alignment has been achieved by hot extrusion, but a lot of fibers fractured during extrusion. The tendency of fiber fracturing increases as the aspect ratio and the amount of fibers increase. Relatively good bonding between fiber and matrix was obtained by the formation of $MgAl_2O_4$ and Mg(Al, Fe)$_2O_4$ at the interface between fiber and matrix. In extruded composites, fiber-strengthening effect was relatively small since a lot of fibers fractured during hot extrusion. On the other hand, dispersion strengthening effect may increase. In order to improve the fiber strengthening effect, it is important to optimize the extrusion condition with consideration of metal flow in extrusion die.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.281-284
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• 2003

The microstructural changes of Al-Zn-Mg-Cu alloy containing Sc during hot extrusion and post heat treatment is investigated. Two kinds of Al-Sc alloys with different alloying elements (B1, B2) are hot extruded to make I-shape bars at 380$^{\circ}C$, then the bars are solution treated at 480$^{\circ}C$ for 2hrs followed by artificial aging at 120$^{\circ}C$ for 24hrs. The interior microstructure of as extruded bar consists of elongated grains, however, fine equiaxed grains are mainly observed around surface. The microstructural gradient suggests that different restoration process can proceed during the hot extrusion. For B1 and B2, different grain growth behaviors are found around the surface during the post heat treatment. Rapid grain growth behavior around the surface is discussed related with the crystallographic orientation of the grain.

• Transactions of Materials Processing
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• v.15 no.2 s.83
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• pp.143-147
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• 2006

Effect of processing condition on the hot extrusion of Al-Zn-Mg-Sc alloy was investigated. For this purpose, hot compression test and FE-simulation were conducted via Thermecmaster-Z and DEFORM-3D, respectively. The microstructure evolution during hot extrusion and post heat-treatment was investigated and deformation mechanisms were analyzed by constructing processing map. FE-simulation results show that the temperature difference between container and billet has considerable influence on the final shape of extruded T-shape bar. The relation between applied load and processing time was predicted by the FE-analysis as well as punch speed vs. stroke chart.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.202-205
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• 2005

Effect of processing condition on the hot extrusion of Al-Zn-Mg-Sc alloy was investigated. For this purpose, hot compression test and FE-simulation were conducted via Thermecmasteer-Z and DEFORM-3D, respectively. The microstructure evolution during hot extrusion and post heat-treatment was investigated and deformation mechanisms were analyzed by constructing processing map. FE-simulation results show that the temperature difference between container and billet has considerable influence on the final shape of extruded T-shape bar. The relation between applied load and processing time was predicted by the FE-analysis as well as punch speed vs. stroke chart.

• Transactions of Materials Processing
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• v.4 no.4
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• pp.322-334
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• 1995

This study presents development of an expert system for process and die design of hot extrusion through square dies. The design of extrusion dies is still an art rathere than a science with increasing complexity of shape and thinness of section. Therefore, most of the die design is still dependent on personal judgement, intuition and experience. The objective of this study is to develop an expert system which includes a rule base system extracted from literatures and experts in the extrusion industry. The system also includes finite element simulation program. The developed system is effectively used to design two types of processes and dies with lead time and trial extrusion.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.62-65
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• 2008

Extrusion characteristics of Mg alloys were studied experimentally. The Al-Zn-Mg alloys, AZ31, AZ6l, AZ80, and AZ91 were extruded with hot hydrostatic extrusion process. The hydrostatic process was efficient to reduce surface friction and extend steady state region in extrusion which made it more convenient to examine deformation behavior of the alloys avoiding the disturbance caused by temporary contact state between billet and die, and billet and container. High pressure was cooperative to expand forming limit of the alloys which were applied on the billet during the extrusion process. Extrusion limits were traced in temperature and extrusion speed domain with changing composition of the alloying elements. Effects of process parameters on extrusion load and microstructure evolution were investigated also.

• Transactions of Materials Processing
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• v.10 no.4
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• pp.311-318
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• 2001

Porthole die extrusion has a great advantage in the forming of long hollow section tubes. It is difficult to produce long hollow section tubes with complicated section by the conventional extrusion process with a mandrel on the stem Because of the limit of the length of mandrel and the complexity of cross section. Porthole die extrusion is affected by many parameters, such as extrusion ratio, extrusion speed, die geometry, porthole number, bearing length etc. Up to now, most of studies about porthole die extrusion have been investigated by experiments or steady state FE-analysis. However, in this paper, porthole die extrusion is analysed by the unsteady state 3D FE-simulation. And the result of unsteady state analysis is compared with the experimental result. Also, the surface state of extruded tubes are examined for the various process conditions.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.436-439
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• 2005

Condenser tube has been used as a component of heat exchanger in automobile and air conditioning apparatus. In this paper, porthole die extrusion that is advantageous to form long hollow section tube is analyzed by direct extrusion of condenser tube with 12 holes. A study on extrusion process is performed through the 3D FE simulation at non-steady state and extrusion experiments. Especially, weldability, extrusion load and die defects were estimated try FE-simulation. This study present the redesigned die of direct extrusion in consideration of the results obtained from FE-analysis.