ABSTRACT
In the realm of modern architecture, the demand for materials that combine strength, durability, and aesthetic flexibility is ever-growing. Addressing this need, this paper presents a study on the innovative use of aluminum extrudates in construction. Focusing on the AA6005 alloy, which is known for its excellent balance of strength, corrosion resistance, and weldability, this research delves into the development of an extrusion process that yields thin-walled, lightweight, yet high-strength structural components. Using FEM simulations, a new extrudate of the AA6005A was developed. It is compatible with standard façade systems, with high-strength properties and a weight reduced by 20% compared to that of conventional extrudates made of the AA6063 alloy. Using CAD engineering and FEM simulations of aluminum extrusion process, an innovative die was designed for the extrusion process, ensuring uniform flow of metal from the bearing and minimizing the elastic deflection of the die. This resulted in an increase in the extrusion velocity of thin-walled extrudate from AA6005A by 24% compared to conventional profiles extruded from AA6063. As part of the research, a trial test was carried out in production conditions and the quality of the extrudates was tested by 3D optical scanning, mechanical and structural properties tests, and microstructure observation.
ABSTRACT
The extrusion of hollow profiles from hard-deformable AlZnMg alloys by using porthole dies encounters great technological difficulties in practice. High extrusion force accompanies the technological process, which is caused by high deformation resistance and high friction resistance in extrusion conditions. As a result of high thermo-mechanical loads affecting the die, a significant loss of dimensional accuracy of extruded profiles can be observed. The different projects of porthole dies for the extrusion of Ø50 × 2 mm tubes from the 7021 alloy were numerically calculated and then tested in industrial conditions by using a press of 25 MN capacity equipped with a container with a diameter of 7 inches (for 7021 alloy and 6082 alloy for comparison). New extrusion die 3 with modified bridge and mandrel geometry and a special radial-convex entry to the die opening was proposed. FEM was applied to analyse the metal flow during extrusion, geometrical stability of extruded tubes and the die deflection. The photogrammetric measuring method was used to evaluate dimensional accuracy of tubes extruded in different conditions and geometrical deviations in porthole dies elements, especially the bridges and the mandrels. Research revealed a high dimensional accuracy of tubes extruded from the 6082 alloy and from the 7021 alloy by using original extrusion die 3, while much higher dimensional deviations were noted for tubes extruded from the 7021 alloy by using extrusion dies 1 and 2, particularly in relation to the circularity, centricity and wall thickness.
