KL-9 Analysis of Material Response to Processing Conditions : A Case Study of Aluminum Extrusion

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In order to fully characterize the metal flow of an aluminum billet during the extrusion process, several modeling and simulation techniques can be employed. Material flow and strain distribution may be studied by a visioplasticity technique using modeling materials. Laboratory scale extrusion tests on engineering materials can be performed to determine the influence of processing parameters. The microstructural response of the material to processing variables may be obtained from a thermal mechanical simultor, which accurately reproduces thermal cycles of extrusion. The crystallographic evolution of grains during thermal-mechanical treatment including the effect of die design and surface deformation conditions can be investigated via Electron Backscatter Diffraction (EBSD). Finally, the stress and temperature gradients can be calculated with Finite Element Modeling (FEM). The combination of these techniques, all applied to different aspects of the extrusion process, can give a full account of how extrusion press conditions affect material flow and microstructure evolution.

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