Continuous extrusion and rolling forming velocity of copper strip

A new copper strip production technology combined with continuous extrusion and rolling technology was proposed. The roll velocity must first be matched with the continuous extrusion velocity to achieve continuous extrusion and roll forming. The bite condition of continuous extrusion was determined, and the compatibility equation between the roll velocity and parameters such as the extrusion wheel velocity, reduction, and strip size was established through mechanical by plastic theoretical calculations. The finite element model of continuous extrusion and rolling was then established by using the TLJ400 continuous extrusion machine with a roll diameter of 200 mm. The relationship between the continuous extrusion and rolling velocities was determined through numerical simulations by software DEFORM-3D, and the accuracy of compatibility equation of velocity was verified.

Effect of process parameters on sheath forming of continuous extrusion sheathing of aluminum

The effect of flow passage length in the die cavity and extrusion wheel velocity on the shape of aluminum sheath during the continuous extrusion sheathing process was analyzed by using finite element methods based on software DEFORM 3D and experimentally validated. The results show that by increasing the flow passage length, the velocity of metal at the cross-section of sheath tends toward uniformity, the values of the bending angles of sheath gradually approach the ideal value of zero and the cross-section exhibits a better shape. The extrusion wheel velocity has negligible effects on the bending shape and cross-section of the sheath product when a long flow passage is used.

Microstructure evolution of Al-Sr master alloy during continuous extrusion

The microstructure evolution of Al–Sr master alloy during continuous extrusion was investigated using X-ray diffractometer, scanning electron microscope and transmission electron microscope. Results indicate that the continuous extrusion process could change the Al4Sr particles of the alloy significantly in size and morphology. The as-cast needle-like Al4Sr particles are broken into small blocks in upsetting zone and crushed heavily in adhesion zone. Plenty of dislocations get tangled up in right-angle bending zone. Al4Sr particles grow in the extending zone. Finally, Al4Sr particles in products are approximately 28 μm in length. Al2Sr particles precipitate during the process. Compared with products by horizontal extrusion, Al4Sr particles by continuous extrusion are finer and distribute more evenly.

Microstructure and properties of Al-0.70Fe-0.24Cu alloy conductor prepared by horizontal continuous casting and subsequent continuous extrusion forming

A novel process for manufacturing A1-0.70Fe-0.24Cu alloy conductor was proposed, which includes horizontal continuous casting and subsequent continuous extrusion forming （Conform）. The mechanical properties, electrical conductivity and the compressed creep behaviour of the alloy were studied. The results indicate that the Conform process induces obvious grain refinement, strain-induced precipitation of AI7CuzFe phase and the transformation of crystal orientation distribution. The processed alloy has good comprehensive mechanical properties and electrical conductivity. Moreover, a better creep resistance under the conditions of 90 ~C and 76 MPa is shown compared with pure A1 and annealed copper, and the relationship between primary creep strain and time may comply with the logarithmic law. The enhanced properties are attributed to the grain refinement as well as the fine and homogeneously distributed thermally stable A1Fe and A17Cu2Fe precipitation phases.

Effects of extrusion speed of continuous extrusion with double billets on welding performance of 6063 Al alloy

During continuous extrusion,the welds were formed at the confluence of two billets.Influences of extrusion wheel rotational speed on micromorphology and properties of welds of 6063 Al alloy were investigated through microstructure observation,tensile test,and SEM analyses.Welding parameters were analyzed using finite element simulation.Results indicated that metal welding was remarkably affected by oxide on outer surface of the double billets during continuous extrusion.Degree of oxide breakage on the welding surface increased due to the evident increase in effective strain rate with increasing extrusion speed.The high temperature induced by increased extrusion speed accelerated the formation of metallurgical bonding.A portion of weld seam lines slowly disappeared,and the proportion of the welding interface that failed to reach metallurgical bonding was also gradually reduced.Tensile strength and elongation of the weld specimen increased with the increase of extrusion speed.

A STUDY OF CONTINUOUS EXTRUSION-CLADDING PROCESSFOR PRODUCTION OF ALUMINUM-CLADDING STEEL WIRE

In this study the process of cladding steel wires with aluminum is investigated experimentally. It is studied how the cladding process and the quality of products are influenced by the aluminum deformation temperature, the wheel speed, the temperature of steel wire, the wire speed and the steel wire tensile force. The relation among the process parameters above is discussed, and the effect of the aluminum deformation temperature on the coating microstructure is analyzed. This paper suggested a reasonable range of process parameters for producing aluminum cladding steel wires.

Defects Formation and Morphology in Large-sized MoSi_2 Rod Prepared by Continuous Extrusion

Incidence of defects in MoSi2 rods prepared by con- tinuous extrusion is dependent on the viscosity of binder. Generally, low viscosity results in surface defects while high viscosity is responsible for inner defects. Cross-section observations indicated that the typical inner defects in sintered MoSi2 rods were large fissure cavity, multiple small holes and single small cavity, of which the characteristic ultrasonic reflection patterns have been experimentally established. Formation of the inner defects is attributed to the inhomogeneous feedstock moving behav- ior in die, which is aggravated with increasing viscosity of binder. Defect free MoSi2 rods were prepared successfully via con. tinuous extrusion by carefully controlling the viscosity of binder.

Force analysis and experimental study of pure aluminum and Al-5%Ti-1%B alloy continuous expansion extrusion forming process

The deformation zone of CONFORM extrusion was divided into primary gripping zone,gripping zone,conical expansion chamber zone,cylindrical zone and sizing zone of die,and corresponding force equilibrium equations were established using the Slab method.The deformation force formulae of CONFORM machine at any wrapping angle with an expansion chamber were obtained.Experiment on pure aluminum and Al-5%Ti-1%B alloy was conducted on the CONFORM machine self-designed.The resistance to deformation of Al-5%Ti-1%B alloy at the deformation temperature of 400℃ and the strain rate of 3.07 s-1 was measured to be 50 MPa using Gleeble-1500 thermal simulation machine.The calculation results of deformation forces for CONFORM process with an expansion chamber for pure aluminum and Al-5%Ti-1%B alloy were given.The experimental CONFORM radial force is in agreement with the radial force obtained by theoretical formula.

Microstructure and Properties of 7075Al Alloy Fabricated by Directly Combined of Spray Forming and Continuous Extrusion Forming under Different Atomization Gas Pressures

A new process consisting of the spray forming and the continuous extrusion forming for manufacturing 7075A1 alloy was proposed. The microstructure evolution, mechanical properties and the resistance to stress corrosion cracking of the alloy were studied. The results indicate that the spray forming process induces obviously grain refinement and greatly lower segregation microstructure. Besides, the Conform process produces finer grains and conduces to more uniform distribution of the precipitates of A1Cu and MgZn2 phases. The fabricated alloy shows good comprehensive mechanical properties and superb performance of stress corrosion resistance. Moreover, a better combination of the mechanical properties and the resistance to stress corrosion cracking could then be obtained under a certain condition of atomization gas pressure of 0.19 MPa. The enhanced properties are attributed to the following factors, which include the grain refinement, the fine and homogeneous distribution of A1Cu and MgZn2 phases, the high density of the extruded products, as well as the discontinuous distribution of the grain boundaries after retrogression and reaging （RRA） heat treatment.

Microstructure and Mechanical Properties of a CuCrZr Welding Joint After Continuous Extrusion

The effect of continuous extrusion forming(CEF) process on the microstructure and mechanical properties of a CuCrZr welding joint was investigated. The experimental results showed that after the CEF process the grains were refined to submicron-scale through dynamic recrystallization,which improved the mechanical properties of the welding joint as well as the base material. Meanwhile,the micron-scale precipitates aggregated at the grain boundaries in the welding process were broken down to smaller ones and recrystallized grains of several micrometers formed around the precipitates after CEF process,which could alleviate the negative effect induced by the micron-scale precipitates during plastic deforming process. Finer grains and smaller micronscale precipitates made contributions to improve the properties of a CuCrZr alloy with a welding joint.

Quantitative mechanisms behind the high strength and electrical conductivity of Cu-Te alloy manufactured by continuous extrusion

The microstructure,mechanical performance,and electrical conductivity of Cu-Te alloy fabricated by continuous extrusion were quantitatively investigated.The results demonstrate that the grain size of the Cu-Te alloy is refined significantly by incomplete dynamic recrystallization.The Cu2Te phase stimulates recrystallization and inhibits subgrain growth.After extrusion,the tensile strength increases from217.8±4.8 MPa to 242.5±3.7 MPa,the yield strength increases from 65.1±3.5 MPa to 104.3±3.8 MPa,and the yield to tensile strength ratio is improved from 0.293±0.015 to 0.43±.0.091,while the electrical conductivity of room temperature decreases from 95.8±0.38%International Annealed Cu Standard(IACS)to 94.0%±0.32%IACS.The quantitative analysis shows that the increment caused by dislocation strengthening and boundary strengthening account for 84.6%of the yield strength of the extruded Cu-Te alloy and the electrical resistivity induced by grain boundaries and dislocations accounts for 1.6%of the electrical resistivity of the extruded Cu-Te alloy.Dislocations and boundaries contribute greatly to the increase of yield strength,but less to the increase of electrical resistivity.

Enhanced electrical,mechanical and tribological properties of Cu-Cr-Zr alloys by continuous extrusion forming and subsequent aging treatment

As a promising material for the new generation of high-speed railway contact wires,the comprehensive optimization of the electrical conductivity,strength,hardness and wear resistance of the Cu-Cr-Zr alloy has received extensive attention.In this paper,a high-performance Cu-1Cr-0.1Zr alloy with an ultimate tensile strength of 599.1 MPa,a uniform elongation of 8.6%,a microhardness of 195.7 HV_(0.2) and an electrical conductivity of 80.07%IACS was achieved by the continuous extrusion forming(CEF)and subsequent peak-aging treatment.The grain refinement strengthening,dislocation strengthening and precipitation strengthening are identified to be responsible for the excellent electrical and mechanical properties of Cu-Cr-Zr alloy.The wear behavior of Cu-Cr-Zr alloy was investigated by examining the evolution of worn surface morphology and subsurface microstructure.The microhardness(H)and reduced elastic modulus(E_(r))of the subsurface below the worn surface measured by nanoindentation were calculated to gage the tribological performance of Cu-Cr-Zr alloy.Results show that the continuously extruded and subsequently peak-aged specimen has the best wear resistance,which indicates that the tribological properties of CuCr-Zr alloy strongly depend on its strength and hardness.It can be concluded that the CEF and subsequent aging treatment process provides a new and high-efficiency procedure for the continuous preparation of Cu-Cr-Zr alloys.

Microstructural and mechanical properties of ZA10 alloy tubes and their weld seams prepared by Conform continuous extrusion

In the present work,Zn-10 Al-2 Cu-0.05 Ti(ZA10)alloy tubes with a diameter of 12.5 mm and wall thickness of 1.2 mm were fabricated by one-pass and double-pass Conform continuous extrusion.A stabilizing heat treatment[350℃,30 min(furnace cooling)+120℃,12 h(air cooling)]was also applied to some of the double-pass tubes to improve the quality of their weld seams.The yield strength,ultimate tensile strength,elongation and expansion ratio of the one-pass continuous extrusion tube were 268.4 MPa,294.3 MPa,13.8%and 5.5%,respectively.Double-pass continuous extrusion improved these values to 278.4 MPa,317.2 MPa,15.4%and 11.4%,respectively.Double-pass tubes also had fewer aggregations of Al-αprecipitates along the welding seam,which improved seam quality and caused cracks to appear in the matrix,away from the weld-affected zone,during expansion testing.Heat-treated double-pass tubes exhibited superior yield strength(283.9 MPa)and ultimate tensile strength(328.5 MPa)but lower elongation(10.2%)and expansion ratios(10.3%).Additionally,the heat-treated tubes exhibited markedly lower elongation at room temperature due to the remarkable blockage of dislocation motions by fine-scale lamellar(α+η)eutectoid structures and a lower size effect when stretched.

Numerical modeling and optimization of process parameters in continuous extrusion process through response surface methodology, artificial neural network & genetic algorithm

The product of high complex profile,high strength,high productivity and excellent material properties with infinite length can be produced by Continuous Extrusion(CE)process.The numerical simulation of Aluminum(AA 1100)feedstock material at different wheel velocities,product diameter,feedstock temperature,die temperature and friction condition has been carried out using 3D simulation tool Design Environment for Forming(DEFORM-3D)in this paper.The development of mathematical model is carried out to investigate the influence of wheel velocity,extrusion ratio,feedstock temperature,die temperature and friction conditions on total load required for the deformation and extrusion of feedstock material through Response Surface Methodology(RSM).The statistical significance of mathematical model is verified through analysis of variance(ANOVA).The most optimum value of extrusion load has been found to be 136.4 kN through iterative process of Genetic Algorithm(GA)using Artificial Neural Network(ANN).The optimized value of input process variables for minimum value of extrusion load obtained has been found to be 13 Revolutions per Minute(RPM)as wheel velocity,5 mm as product diameter,0.95 as friction condition,650◦C as feedstock temperature and 550◦C as die temperature.This paper with proposed methodology will be helpful for industries working in the area of CE in terms of minimizing energy consumption during production process of bus bars,tubes,wires,cables,sheets,plates,strips,etc.

Dynamical Solidification Behaviors and Metal Flow during Continuous Semisolid Extrusion Process of AZ31 Alloy

In this paper, a novel near-net-shape forming process, continuous semisolid extrusion process （CSEP） of AZ31 alloy was proposed, and the dynamical solidification behaviors and metal flow during the process were firstly investigated. During casting AZ31 alloy by this process, non-uniform microstructure distributions and non- equilibrium solidification region near the roll surface were found in the roll-shoe gap. Microstructural evolution from dendrite to rosette and spherical grains was observed during the casting by CSEP. Casting temperature, roll-shoe gap width and cooling ability have great effect on casting process and metal flow, so these factors should be carefully controlled, a proper casting temperature of 710-750℃ is suggested. The white α phases were strongly stretched during the processing, and the remnant liquids are correspondingly distributes along the solid phase boundaries and also show stripped lines.

Fabrication of ultra-high strength magnesium alloys over 540 MPa with low alloying concentration by double continuously extrusion

We prepare a new type of patented biodegradable biomedical Mg-Nd-Zn-Zr(JDBM)alloy system and impose double continuously extrusion(DCE)processing.The lowest processing temperature is 250℃for JDBM-2.1Nd and 310℃for JDBM-2.8Nd,which increases with the Nd concentration.The highest yield strength of 541 MPa is achieved in JDBM-2.1 Nd samples when extruded at 250℃and the elongation is about 3.7%.Moreover,the alloy with a lower alloying element content can reach a higher yield strength while that with a higher alloying element content can reach a larger elongation after DCE processing.However,when extruded under the same conditions,the alloy with a higher alloying contents exhibits better tensile properties.

Study on grain refinement of interstitial-free steel during continuous frictional angular extrusion

To explore the application of severe plastic deformation for grain refinement in steel production, a new method called continuous frictional angular extrusion （CFAE） was applied to refine the grain of interstitial-free steel. The deformation was carried out at room temperature and individual sheet specimens were processed in different number of passes. An overall grain size of 200nm was achieved after 8 passes and the proportion of high-angle boundaries to the total boundaries was more than 60%. Through the characterization of high resolution EBSD, X-ray diffraction （XRD） and hardness testing,this paper discussed the evolution of microstructures and textures during deformation and explored the development direction of the method.

Extrusion force analysis of aluminum pipe fabricated by CASTEX using expansion combination die

To determine the extrusion force of pipe fabricated by continuous casting and extrusion (CASTEX) using an expansion combination die, the metallic expansion combination die was divided into diversion zone, expansion zone, flow dividing zone, welding chamber, and sizing zone, and the corresponding stress formulae in various zones were established using the slab method. The deformation zones of CASTEX groove were divided into liquid and semisolid zone, solid primary gripping zone, and solid gripping zone, and the formulae of pipe extrusion forces were established. Experiments were carried out on the self-designed CASTEX machine to obtain the aluminum pipe and measure its extrusion force using the expansion combination die. The experimental results of radial extrusion force for aluminum pipe are in good agreement with the calculated ones.

Deformation mechanisms and microstructural characteristics of AZ61 magnesium alloys processed by a continuous expansion extrusion approach

The unique continuous extrusion-based severe plastic deformation approaches were proposed recently to process high-performance magnesium(Mg)alloys,while the in-depth deformation mechanisms under such complicated thermomechanical conditions were not well understood.In the present work,the fundamental deformation behaviors of AZ61 Mg alloy from 25 to 400°C were firstly examined under uniaxial compression deformation.Then the deformation mechanisms and microstructural characteristics of AZ61 Mg alloy during continuous expansion extrusion forming(CEEF)were systematically investigated by microstructural observations,finite element and cellular automata simulations.The results showed that the continuous evolutions of temperature,larger strain level and complex stress state with strain rate range of 0∼5.98 s−1 during CEEF brought the distinctive dynamic recrystallization behaviors and texture development in AZ61 Mg alloy,which were different to that of uniaxial compression deformation.In details,a remarkable grain refinement was achieved via CEEF processing due to the simultaneous actions of continuous dynamic recrystallization(CDRX)and discontinuous dynamic recrystallization(DDRX).Gradually enhanced CDRX were observed from center to edge region,which had significant effects on the texture distribution and texture strength.The c-axis of most grains rotated under distinctive shear strain following parabolic metal flow,resulting in stable fiber texture.In addition,the evolution of the internal texture of the alloy led to an obvious increase in the Schmid factor for the activation of basalc+aslip system.©2022 Chongqing University.Publishing services provided by Elsevier B.V.on behalf of KeAi Communications Co.Ltd.

Effect of Accumulative Strain on Grain Refinement and Strengthening of ZM6 Magnesium Alloy During Continuous Variable Cross-Section Direct Extrusion

In order to study the influence of die combination on continuous variable cross-section direct extrusion （CVCDE） in the extrusion process, the accumulative strain formula is derived, and it can be known that the extrusion ratio of various stages directly determines the size of corresponding stage strain by formula. In this paper, as an example of the two interim dies, three die combinations of different angles and extrusion ratio are designed. Aviation magnesium alloy ZM6 is studied, and the results show that dynamic recrystallization is even more complete when continuous shear deformation occurs, so that the refinement and homogenization of microstructure are obtained. By the use of different die combinations, the accumulative strain increases under the conditions of same total extrusion ratio. Thus, the refined crystalline strengthening effect of extrusion deformation can be further analyzed. Due to the dead-zone defects, the actual accumulative strain decreases significantly and the effect of microstructure and performance improvements also decreases with it. Therefore, the optimal design of die combination is the key to the process and product of CVCDE, which provides a scientific basis for the development of severe plastic deformation.