Feasibility study of a novel multi-container extrusion method for manufacturing wide aluminium profiles with low force

Extrusion profiles are extensively used in industries and any improvement the process could potentially have a large impact on energy cost savings. In this study, novel extrusion method, namely multi-container extrusion, was proposed for producing thin-walled wide aluminium components with low force. Its basic principle is to enable multiple billets be welded forced through die orifice simultaneously. To demonstrate its feasibility, series of studies been conducted including experimental design set-up microstructural mechanical characterisations extruded components, comparison existing method. A three-container tooling designed manufactured produce hollow plasticine alloy AA6063. Optical microscopic observations tensile tests were carried out different positions AA6063 extrudates. For specimens near extrudate front (8 mm 23 away), fractures occurred exactly along distinct welds which formed when individual met inside during extrusion. Further away from (83 mm, 98 113 mm), hardly observed, outside welds, indicating that good welding quality can obtained process. Compared conventional porthole significantly reduce required force about 15 % extruding same profile. This study demonstrates method form greatly requirement.