Aluminum Extrusion Technology Seminar (2012)

The 10th Aluminum Extrusion Technology Seminar – ET’12

May 15-18, 2012
Miami, Florida, USA

ET ’12 Proceedings – Set (Book & Flash Drive)

ET ’12 INDIVIDUAL PAPERS

Volume I: Brief Contents

Extrusion/Die Practical
Extrusion Equipment
Extrusion/Die Theoretical

EXTRUSION/DIE PRACTICAL

The Dynamics of Dead Zones in Hot Extrusion
The Influence of Die Bearing Geometry on Surface Recrystallization of 6xxx Extrusions

Tooling and Performance

Flow of Billet Surface Material During Extrusion of Al Alloys; Effect of Billet Quality and Process Conditions
6005A: Practical Evidence of Advantages for Extruders and Their Customers
Improving the Wear and Extrusion Speed of Extrusion Tools with a Unique Duplex Surface Treatment
Developments in Hot Work Tool Steels: Looking Beyond the Basics toward True Savings in Aluminum Extrusion Tooling
Development of a New Aluminum Extrusion Hot Work Tool Steel
Increased Productivity using CVD-Coated Insert Tooling

Dies, Inserts, and Coatings

Die Heating Excellence and Energy Savings
Dies Digital Archive and Remote Correction System; Time and Cost Savings for Correction Departments
Optimal Die Prefill Practices for Soft Alloy Extrusion
Weldability Testing of Hard Deformable Aluminum Alloys Intended for Extrusion through Porthole Dies
Hot Extrusion of Al/SiC Powder through Porthole Die
A Study of Multi-material Die Insert Failure Mechanism in Aluminum Extrusion
Tribological Investigation on CVD-Coated Extrusion Dies

Best Practices

Helping the Customer – Part Two
Significant Extrusion Speed Increase Using Liquid Nitrogen to Eliminate Overheating of Dies during Extrusion Process
Simple Temperature Measurement Techniques for Extruders: Straightforward Solutions in a Tough Market

Hard Alloys

Development and Application of New AA2013 Alloy
Extrusion of Hard-Alloy, Thin-Wall Hollow Profiles
New Developments in Extrusion of 2xxx Alloys with Solution Heat Treatment on the Press

EXTRUSION EQUIPMENT

Heavy Duty Extrusion Presses for Large Profile Applications

For Large Profiles

Nondestructive Examination of Extrusion Press Hydraulic Cylinder Pressure Walls
Large Press Handling Systems
Extrusion Equipment Dedicated to Large Profile Press Line

Safety and Automation

Extrusion Press Safety from a Hydraulic System Design Perspective
A New Extrusion Press Concept
Evaluation of Process Mechanism and Parameters for Automated Stretching Line
Extruder Automation Comes of Age: A Review and Outlook of Automation Systems for Aluminum Extruders
Dummy Block Lubrication Best Practices

Container and Tooling

Interactions between Mechanical and Thermal Stresses in Extrusion Containers
New Materials and Intelligent Design on Extrusion Tooling

Die Heating and Preparation

Phase-Controlled Nitriding and Nitrocarburizing Applied to Reduce Flaking, Brittleness, and Improve Die Life
Die Cleaning and Polishing Production Experience
Innovative Integrated Plants of Die-Cleaning and Caustic Soda Recovery: Case History of a Big and Modern European Plant

Efficiencies

Can Automated Die-Polishing Help Your Extrusion Output and Efficiency?
Improving Recovery with Rotary Log Welding
Efficiency Optimization of the Aluminium Extrusion Plants
Gas-Induction Inline Oven

EXTRUSION/DIE THEORETICAL

Surface Pick-up Formation: New Limits in the Limit Diagram

Friction and Pickup

Analyzing the Tribological Phenomena in Hot Extrusion Processes by Using New Torsion-Tribo Test
Determination of Friction Behavior in Extrusion Processes with a New Experimental Method

Benchmark, Finite-Element Method, Metal Flow

A Review on FEM Codes Accuracy for Reliable Extrusion Process Analysis: the Extrusion Benchmark 2009 and 2011
Study of Effects of Variations in Process Parameters on the Extrusion Process by Use of Finite–Element Simulations
Application of Numerical Simulation Technology to Optimize Die Designs for the Production of Complex Aluminum Profiles
Constitutive Equations for Hot Extrusion of AA6005A, AA6063 and AA7020 Alloys
The State of the Art in Aluminum Extrusion Simulation Using the Finite Element Method

Weld and Finite-Element Method

Prediction of Position and Extent of Charge Welds in Hollow Profiles Extrusion
Practical Approach to Computer Simulation and Optimization of Complex Thin Profile Extrusion
Metal Flow Analysis in a Complex Die

Modeling, Microstructure and Simulation

Development of a Numerical Method for Simulation of Aluminum Extrusion Processes with Modeling of Microstructure
Modeling the Extrusion Process and the Microstructure Evolution for Hot Extrusion of AA3xxx Aluminum Alloys
Investigation of the Dynamic Grain Structure Evolution during Hot Extrusion of EN AW–6082
Through Process Modeling (TPM) of Grain Structure Evolution in 6xxx Series Aluminium Extrusions
Deformation Prediction of Porthole Dies after Multiple Extrusion Cycles
Distortion Mechanisms due to the Cooling Process in Aluminum Extrusion
Functional Data Analyses in Control of Extrusion Process

Composites and Nonconventional Materials

Influence of the Steel-Reinforcement Geometry on Position and Embedding Quality in Discontinuously-Reinforced, Co-Extruded Aluminum Profiles
Extrusion of Ingot and Powder Metallurgy Aluminum Matrix Composites Profiles
Simulation-Aided Design of Porthole Dies for Magnesium Alloys Extrusion

Volume II: Brief Contents

Billet Process & Equipment
Management Issues
Value-Added Processes

BILLET PROCESS & EQUIPMENT

The Influence of Iron Content on the Tensile Properties and Anodizing Response of AA6060 Extrusions

Alloys

Influence of Varying the Chemical Composition on the Extrusion Performance of AA6060 and AA6063 Alloys
High Speed Alloys: On the Optimization of 6xxx Alloys for Medium Strength Requirements
Influence of Fe and Mn Content on 6xxx Extrusion Alloys
Composition Analysis Uncertainty: Impact, Common Causes and Use of Production Limit Offsets to Ensure On-Composition Product
Effect of a New Solution and Aging Treatment on the Microstructure and Tensile Properties of the H755 Aluminum Alloy
High Performance AA6063 Designed to Meet 6xxx Medium Strength Alloy Properties

Casting, Casthouse, Environmental Health & Safety

Large Diameter Billet Casting Technology
Effects of Different Lubricating Oils and Ceramic Ring Overhang (CRO) on the Surface Appearance of 6xxx series Alloy Billets
Transient Molten Metal Quality at the Start and End of DC Casting and the Impact on Extrusion
Molten Metal Safety in Aluminum DC Billet Casting
Reducing Environmental Impacts in the Casthouse
Minimizing Production Shutdowns through Effective Application and Maintenance of Safety Pit Coatings

Homogenization

Homogenization Aspects, Continuous versus Batch in an Integrated Modern Casthouse
A New Method to Control Load Temperature in Batch Homogenization Process
Homogenization of Al-Mg-Si Alloy Billets – Myths and Facts

MANAGEMENT ISSUES

Is Operational Modeling Worth the Effort? Using Simple Spreadsheet Models of Extrusion Operations to to Ask “What if”? Questions Regarding Equipment and Profiles

Operations

Six Sigma Methodology Analysis Applied to Extrusion Plant
The Practical Application of Advanced Linear Programming Modeling Techniques to Optimize Extrusion Operations
Flow Stress and Knowledge-Based Superextruders
Down Time Monitoring & Extrusion Process Monitoring
Extrusion Process Equipment Upkeep for Better Plant Performance — “Mission 95”
How Data Integrity can be Used as a Simple, Effective Means to Continuously Improve Extrusion Results
Using Data to Calculate Optimized Log Lengths and Mill Lengths in an Aluminum Extrusion Operation – A Case Study
Search For Similar Profiles through Pattern Matching Algorithms: Effectiveness and Advantages for Extrusion Companies
Employee Motivation in an Aluminum Extrusion Operation

Markets and Applications

Aluminum Consumption and Aluminum Extrusion Industry in China
Leveraging the Design Advantages of Aluminum Extrusions vs. Competitive Materials – How the Aluminum Extrusion Industry can Expand its Markets
Global Aluminium Applications in Electric Vehicles and Charging Infrastructure
Economics of Aluminum Extrusion for Aerospace Applications

Die-Related

Optimization of Die Wear and Tear for 6063 Alloy
Improvements in Aluminum Extrusion Profitability through Competence

Sustainability and Recycling

Constructing the Sustainable Path Forward
The Effect of Die Design on the Mechanical Properties of Profiles Recycled From AA6060 Chips by Hot Extrusion
Trivalent Chromium: A “Green” Solution to Hexavalent Chromium
Green and Smart Anodizing: The Anodizing of the Future Available Today
Aspects of Preferential Grain Etching During Alkaline Pre-Etching Step Before Anodizing of Aluminium Profiles.

VALUE-ADDED PROCESSES

Trace Elements and their Impact on the Surface Finishing Characteristics of Aluminum Extrusions

Metallurgical Factors

Factors Affecting the Machinability of Al-Mg-Si Extrusions
Metallurgical Analysis of Surface Streaking Defect in AA6060 Extrudate

Solar

Aluminum in Solar: Manufacturing Cost Analysis of CSP Structures
Issues on the Design and Fabrication of Extruded Aluminum Framing for the Solar Industry

Process Improvements

Stretch Wrapping of Master Bundles and Wooden Battens
New Developments in Extrusion of Profiles with Variable Curvatures and Cross-Sections
A New Liberalization Trend in the Aluminum Fenestration Industry

Finishing

The XS Plant: The Vertical Line for Window Makers
Advanced Decoration Technology for Aluminum
The World Highest Vertical Powder Coating Line for Aluminium Profiles
Acid Etching for Extruded Aluminium: Technical, Economical and Environmental Aspects

Design Developments

Innovative Extrusions for Value-Added Applications
Developments in the Design of Aluminum Extrusions for Structural Applications
Review of Past Innovations and Recent Improvements in Aluminum Extrusion Production: from Alloy to Process Development