Analysis of solid-state welding in extruding wide aluminium hollow profiles using a new three-container extrusion system

A novel multi-container extrusion has recently been proposed to extrude multiple billets simultaneously for manufacturing thin-walled wide engineering components with greatly reduced force. The metal flow behaviour and solid-state welding in the process are crucial factors that influence final product quality industrial application. In this study, AA6063 hollow profiles were extruded by three-container technology under different combinations of temperature speed. bonding welds formed between adjacent during was experimentally evaluated via tensile tests specimens at positions extrudates. three-dimensional numerical model established validated characterise welding. Ten points first 140 mm weld extrudate traced investigate paths related physical information such as pressure, effective stress, velocity strain rate reveal formation mechanism. simulated results showed whole includes five stages, i.e. separation stage, smooth chamber filling die bearing breakthrough stage steady stage. By evaluating testing results, pressure-time (Q) criterion found able evaluate individually each condition, while pressure-time-flow (K) appeared suitable predict various conditions within a small range critical limits.