Porthole die extrusion of aluminum 6063 industrial scrap by shear assisted processing and extrusion

Whalen, Scott A.; Taysom, Brandon Scott; Overman, Nicole R.; Reza-E-Rabby, Md; Qiao, Yao; Richter, Thomas; Skszek, Timothy W.; DiCiano, Massimo

doi:10.1016/j.mfglet.2023.01.005

Porthole die extrusion of aluminum 6063 industrial scrap by shear assisted processing and extrusion

Journal Article · Tue Mar 28 00:00:00 EDT 2023 · Manufacturing Letters

DOI:https://doi.org/10.1016/j.mfglet.2023.01.005· OSTI ID:1969702

^[1]; ^[1]; ^[1]; Reza-E-Rabby, Md ^[1]; ^[1]; Richter, Thomas ^[2]; Skszek, Timothy W. ^[1]; DiCiano, Massimo ^[2]

Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Magna International, Inc., Aurora, ON (Canada)

Shear Assisted Processing and Extrusion (ShAPE) is presented as a new manufacturing technology for converting aluminum scrap directly into extruded products. In this work, a porthole die configuration is integrated within the rotating ShAPE process to extrude circular, square, trapezoidal, and two-cell trapezoidal profiles from aluminum alloy 6063 industrial scrap. This is the first time that a rotating billet has been used to impart severe plastic deformation (SPD) during extrusion of noncircular profiles. Microstructural characterization is presented for a trapezoidal profile having an average grain size of 6.7 µm in the as-extruded condition. Dimensional stability was evaluated by measuring wall thickness along the extrusion length; the thickness varied by <5%. Round tubes achieved yield strength (246.9 ± 10.4 MPa), ultimate tensile strength (270.8 ± 9.6 MPa), and uniform elongation (16.5 ± 2.4%) exceeding industry standards.

View Accepted Manuscript (DOE)

Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO)

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 1969702

Report Number(s):: PNNL-SA-179478

Journal Information:: Manufacturing Letters, Journal Name: Manufacturing Letters Vol. 36; ISSN 2213-8463

Publisher:: Society of Manufacturing Engineers, ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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